Fracture mechanics solutions to spot welds

Abstract

Notch stress, stress intensity factors and J-integral at a spot weld are generally expressed by structural stresses around the spot weld. The determination of these parameters are then simplified as determining the structural stresses that can be calculated by a spoke pattern in finite element analysis. Approximate stress formulas for structural stress, notch stress and equivalent stress intensity factor are given for common spot-welded specimens. With the aid of the formulas, test data in terms of the original load can be easily transformed into the data in terms of the structural stress, notch stress or equivalent stress intensity factor at the spot weld. The formulas also facilitate the transfer of test data across different specimens. A measuring method is given for lap joints. The strain gauge technique developed for the tensile-shear specimen shows that all the structural stress, notch stress, stress intensity factors and J-integral at the spot weld can be determined by two strain gauges attached only to the outer surface of one sheet. The results presented here should be helpful for the analysis and testing of spot welds and for developing measuring methods for spot welds.