Evaluation of dissimilar TIG welded joints of novel high strength low alloy steel for automotive applications: Experiment and numerical comparative approach

Abstract

Modern automotive, aerospace, and manufacturing sectors use tungsten inert gas (TIG) welding widely as a critical procedure due to the weld's quality and joint efficiency. In this study, mechanical characterization of TIG-welded joints of high strength low alloy (HSLA) steel with two different grades (S1 and S2) was performed experimentally and mechanical properties were calculated in terms of hardness profile along the weldment and load-displacement curves. True stress-strain curves of base metal, heat-affected zone, and melted zones were used for calibration of the 8-node solid numerical model. The highest hardness value of 386 HV was obtained in the melted zone whereas a softening zone was observed in the heat-affected zone (HAZ) of S2 where the Vicker's microhardness value was 270 HV. During the comparison of simulation results with experimental data, it was found that the overall error was less than 5% which reflects a good accuracy of material models used for numerical modeling. A higher ultimate tensile strength was found in similar S1-S1 steel joints as compared to similar S2-S2 and dissimilar S1-S2 steel joints. Furthermore, the results of simulations revealed that the maximum von Mises stress (1050 MPa) concentrations were found in the HAZ of a similar S1-S1 welded joint, whereas the minimum von Mises stresses (880 MPa) in S2-S2 welded joint, and intermediate von Mises stresses (1010 MPa) on the side of S1 HAZ in S1-S2 dissimilar welded joint. The results of simulations and experimental study of TIG welding joints show good agreement with reasonable accuracy.