This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Fatigue Evaluation Procedure Development for Aluminum Alloy Spot Welds Using the Battelle Structural Stress Method
Technical Paper
2015-01-0545
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
As the automotive industry seeks to remove weight from vehicle chasses to meet increased fuel economy standards, it is increasingly turning to composites and aluminum. In spite of increasing demands for quality aluminum alloy spot welds that enable more fuel efficient automobiles, fatigue evaluation procedures for such welds are not well-established.
This article discusses the results of an evaluation Battelle performed of the fatigue characteristics of aluminum alloy spot welds based on experimental data and observations from the literature. In comparison with spot welds in steel alloys, aluminum alloy spot welds exhibit several significant differences including a different hardness distribution at and around the weld, different fatigue failure modes, and more.
The effectiveness and applicability of the Battelle structural stress-based simplified procedure for modeling and simulating automotive spot welds has previously been demonstrated by Battelle investigations. After considering the fatigue characteristics of aluminum alloy spot welds, it was concluded that the Battelle structural stress-based simplified procedure and the master S-N curve approach based on this procedure were adaptable to aluminum spot welds.
Battelle researchers used structural stress-based simplified procedure to compare available fatigue data for spot welds in aluminum alloys were with the existing master S-N fatigue curve for welded aluminum alloys. The existing curve contained data for numerous fusion and friction-stir welds. The comparison clearly showed that the weld procedure did not significantly affect the fatigue life of good quality welds, and that a single master S-N curve was possible for spot, fusion and friction-stir welds in the aluminum alloys considered, when the equivalent Battelle structural stress range was used.
Authors
Citation
Hong, J., "Fatigue Evaluation Procedure Development for Aluminum Alloy Spot Welds Using the Battelle Structural Stress Method," SAE Technical Paper 2015-01-0545, 2015, https://doi.org/10.4271/2015-01-0545.Also In
References
- Sun , X. , Stephens , E. , Davies , R. , Khaleel , M. et al. Effects of Failure Modes on Strength of Aluminum Resistance Spot Welds SAE Technical Paper 2005-01-0906 2005 10.4271/2005-01-0906
- Thornton , P. H , Krause , A. R , and Davies , R. G The Aluminum Spot Weld Welding Journal 75 101-s 108-s 1996
- Rupp , A. , Störzel , K. , and Grubisic , V. Computer Aided Dimensioning of Spot-Welded Automotive Structures SAE Technical Paper 950711 1995 10.4271/950711
- Shi , Y. and Guo H. Fatigue Performance and Fatigue Damage Parameter Estimation of Spot Welded Joints of Aluminum Alloys 6111-T4 and 5754 Fatigue & Fracture of Engineering Materials & Structures 36 1081 1090 2013
- Wang , P. C , Chisholm , S. K , Banas . G. , and Lawrence , F. V , Jr. The Role of Failure Mode, Resistance Spot Weld and Adhesive on the Fatigue Behavior of Weld-Bonded Aluminum Welding Journal 74 41-s 47-s 1995
- Uematsu , Y. , Kurita , T. , Murata , S. , and Tokaji , K. Fatigue Behaviour of Resistance Spot Welded Joints of Al-Mg-Si Alloy Journal of the Society of Materials Science, Japan 57 8 808 831 2008
- Uematsu , Y. , and Tokaji , K. Comparison of Fatigue Behaviour between Resistance Spot and Friction Stir Spot Welded Aluminium Alloy Sheets Science and Technology of Welding and Joining 14 1 62 71 2009
- Hassannifard , S. , Zehsaz , M. and Tohgo , K. The Effects of Electrode Force on the Mechanical Behaviour of Resistance Spot-Welded 5083-O Aluminum Alloy Joints Strain 47 e196 e204 2011
- Florea , R.S , Bammann , D.J , Yeldell , A. , Solanki , K. N , and Hammi , Y. Welding Parameters Influence on Fatigue Life and Microstructure in Resistance Spot welding of 6061-T6 Aluminum Alloy Materials and Design 45 456 465 2013
- Dong , P. , Hong , J.K , and Cao , Z. A Mesh-Insensitive Structural Stress Procedure for Fatigue Evaluation of Welded Structures IIW Doc. XIII-1902-01/XV-1089-01 2001
- Dong , P. , Hong , J.K , and Cao , Z. Structural Stress Based Master S-N Curve for Welded Joints IIW Doc. XIII-1930-02/XV-1119-02 2002
- Dong , P. and Hong , J. K The Master S-N Curve Approach to Fatigue Evaluation of Offshore and Marine Structures OMAE 2004-51324 2004
- Dong , P. and Hong , J.K The Master S-N Curve Approach to Fatigue of Piping and Vessel Welds Welding in the World 48 1/2 28 36 2004
- Dong , P. , Hong , J. K , and De Jesus , A. M. P. Analysis of Recent Fatigue Data Using the Structural Stress Procedure in ASME Div 2 Rewrite Trans. ASME Journal of Pressure Vessel Technology 139 3 355 362 2007
- Dong , P. , Hong , J. K , Osage , D.A , Dewees , D.J , and Prager , M. The Master S-N Curve Method An Implementation for Fatigue Evaluation of Welded Components in the ASME B&PV Code, Section VIII, Division 2 and API 579-1/ASME FF-1 Welding Research Council Bulletin 523 Welding Research Council 2010
- 2007 ASME Boiler and Pressure Vessel Code, Section VIII, Div.2 ASME 2007
- API Standard 579-1/ASME FFS-1 Fitness for Service, API 2007
- Dong , P. and Hong , J. CAE Weld Durability Prediction: A Robust Single Damage Parameter Approach SAE Technical Paper 2002-01-0151 2002 10.4271/2002-01-0151
- Potukutchi , R. , Agrawal , H. , Perumalswami , P. , and Dong , P. Fatigue Analysis of Steel MIG Welds in Automotive Structures SAE Technical Paper 2004-01-0627 2004 10.4271/2004-01-0627
- Lightweight Chassis Structures Team As-built Models and Development of Fatigue Analysis Methodology ASP 601 Lightweight Rear Chassis Project Report, Auto/Steel Partnership 2008
- Dong , P. , Hong , J.K , Potukuchi , R. , Agrawal , H. Master S-N Curve Development and Validations for Aluminum MIG and Laser Welds IIW Doc. XIII-2035-04/XV-1172-04 2004
- Hong , J. and Forte , T. Development of Friction Stir Weld Fatigue Evaluation Procedure Using Battelle Structural Stress Method SAE Int. J. Mater. Manf. 7 2 432 438 2014 10.4271/2014-01-0909
- Kang , H. T , Dong , P. , and Hong , J. K Fatigue Analysis of Spot Welds Using a Mesh-Insensitive Structural Stress Approach International Journal of Fatigue 29 1546 1553 2007
- Rahman , M.M , Bakar , R. A , Noor , M. M , Rejab , M. R. M. , and Sani , M. S. M. Fatigue Life Prediction of Spot-Welded Structures: A Finite Element Analysis Approach European Journal of Scientific Research 22 444 456 2008
- Hong , J. The Development of a Simplified Spot Weld Model for Battelle Structural Stress Calculation SAE Int. J. Mater. Manuf. 4 1 602 612 2011 10.4271/2011-01-0479
- Maddox , S. J Fatigue Design of Welded Structures Engineering Design in Welded Constructions Pergamon Oxford 31 56 1992
- Radaj , D. and Sonsino , C. M Fatigue Assessment of Welded Joints by Local Approaches Abington Publishing Cambridge, England 1998
- Hong , J. K and Forte , T. P Fatigue Evaluation Procedures for Multiaxial Loading in welded Structures Using Battelle Structural Stress Approach OMAE 2014-23459 2014
- Hong , J. and Forte , T. Development of Fatigue Evaluation Procedure for Weld-Bonded Joints Using the Battelle Structural Stress Method SAE Technical Paper 2012-01-0477 2012 10.4271/2012-01-0477
- Gean , A. Westgate , S.A , Kucza , J.C , and Ehrstrom , J.C Static and Fatigue Behavior of Spot-Welded 5182-0 Aluminum Alloy Sheet Welding Journal 78 80-s 86-s 1999
- Chang , B. H , Du , D. , Shi , B. , Zhou , Y. , Wang , Z. , and Heidarzadeh Effect of Forging Force on Fatigue Behavior Spot Welded Joints of Aluminum Alloy 5182 Transactions of ASME, Journal of Manufacturing Science and Engineering 129 95 100 2007
- Han , L. , Thornton , M. , Li , D. , and Shergold . M. Effect of Governing Metal Thickness and Stack Orientation on Weld Quality and Mechanical Behaviour of Resistance Spot Welding of AA5754 Aluminium Materials and Design 32 2107 2114 2011
- Kim , J.-S. , Kim , C. , Jin , T.-E. , and Dong , P. Mean Load Effect on Fatigue on Welded Joints Using Structural Stress and Fracture Mechanics Approach Nuclear Engineering and Technology 38 277 284 2006
- Weld Fatigue Analysis of Aluminum Alloy Joints Battelle Structural Stress JIP Year 3 Material Battelle 2013
- Hobbacher , A. Recommendations for Fatigue Design of Welded Joints and Components IIW Document IIW-1823-07 2008
- Eurocode 9: Design of Aluminium Structures - Part 1-3: Structures Susceptible to Fatigue, EN 1999-1-3 2007