Comparative analysis of resistance spot welded and weld bonded joint of al 6082-T651

Abstract

A comparative experimental analysis of resistance spot welded and weld bonded joint is done to confirm the superiority of weld bonded joint. The joints are observed at different weld nugget pitch distances by varying the distance between two weld nuggets to 10 mm and 30 mm for various weld nugget diameters. The effect of variation in weld nugget pitch distance for a particular weld nugget diameter has been significant in resistance spot welded joint while its effect on weld bonded joint is negligible. Weld nugget size at a particular pitch distance affect both the resistance spot welded joint and weld bonded joint. Finite element model for resistance spot welded and weld bonded joint have been developed at these weld nugget pitch distances to analyze these two joints in greater detail. It is found that in resistance spot welded joint, the weld nuggets bear the major fraction of the load applied and the maximum stress concentration develops at the edges of the weld nuggets which interact more at lower weld nugget pitch distance making the joint weaker. While in weld bonded joint the applied load is shared jointly by the adhesive layer and the weld nuggets with the generated stress being evenly distributed showing negligible effect of weld nugget pitch distance on the joint strength.