Abstract
Failure mode is a qualitative measure of resistance spot weld performance. To ensure reliability of resistance spot welds during vehicle lifetime, process parameters should be adjusted so that the pullout failure mode is guaranteed. In this paper, the effect of electrode force on the failure mode of drawing quality specially killed (DQSK) steel resistance spot welds during the quasistatic tensile-shear test is investigated. Results showed that there is a minimum weld nugget size to ensure pullout failure mode. It was found that increasing electrode force decreases fusion zone size and therefore leads to transition of failure mode from pullout to interfacial mode.
Highlights
Resistance spot welding is considered as the dominant process for joining sheet metals in automotive industry
It is well established that the geometrical attributes of spot welds, weld nugget size, are the most important controlling factors determining the mechanical strength of resistance spot weld (RSW) [8,9,10,11,12,13,14,15]
4 Conclusions The following conclusions can be drawn from this study: (1) Increasing electrode force decreases fusion zone size due to reducing the contact resistance
Summary
Resistance spot welding is considered as the dominant process for joining sheet metals in automotive industry. The resistance spot weld (RSW) failure occurs in two modes: interfacial and pullout. It is well established that the geometrical attributes of spot welds, weld nugget size, are the most important controlling factors determining the mechanical strength of RSWs [8,9,10,11,12,13,14,15].
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