Fracture toughness of the molten zone of resistance spot welds

Abstract

A methodology for measuring the fracture toughness at crack initiation and the crack extension resistance of the molten zone of resistance spot welds under Mode I loading has been developed. The cross tensile test of U-shaped specimens was modified by crack growth monitoring and stress intensity factor determination. The resulting values of fracture toughness at crack initiation are independent of the nugget diameter and of the base material mechanical properties. The crack extension resistance seems to depend on base material mechanical properties and nugget diameter. Mixed cleavage + ductile mode associated to medium values of fracture toughness (54–90 $$\text{ MPa }\,\text{ m }^{0.5}$$ ) suggested a ductile to brittle transition behaviour. The relatively low fracture toughness (55–59 $$\text{ MPa } \,\text{ m }^{0.5}$$ ) associated to full interfacial ductile failure was quantitatively related to the high number density of small particles in the molten zone. This study opens the possibility to apply the local approach to fracture under monotonic loading to interfacial failure of resistance spot welds.