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Effect of governing metal thickness and stack orientation on weld quality and mechanical behaviour of resistance spot welding of AA5754 aluminium

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Han, L., Thornton, M. (Martin), Li, Dezhi and Shergold, M.. (2011) Effect of governing metal thickness and stack orientation on weld quality and mechanical behaviour of resistance spot welding of AA5754 aluminium. Materials & Design, Volume 32 (Number 4). pp. 2107-2114. ISSN 0264-1275

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Abstract

A study was carried out to investigate the effect of governing metal thickness (GMT) and stack orientation on weld quality and mechanical behaviour of resistance spot welded (RSW) AA5754 aluminium. Individual samples from 27 different joint stacks in three test geometries; lap-shear, coach-peel and cross-tension were evaluated for quasi-static and fatigue performance; micro examination was also conducted on some of the samples to assess weld quality. The results derived from over 1000 samples show that: the GMT has a significant effect on welding quality by controlling progression of weld nugget from underdeveloped to over penetrated. The GMT also determines the feasible quasi-static joint strength regardless of stacks in the three joint geometries tested, though the effect differs with respect to test geometry. The fatigue behaviour is dominated by the effect of GMT on attainable weld size, overall joint stiffness and stress concentration, providing good quality of weld nuggets is achieved. No notable effect of stack orientation on weld quality and joint strength was found with respect to the joint stack asymmetry and welding orientation to the electrodes. These fundamental relationships between weld qualities, joint strength, GMT and stack orientation for RSW of aluminium will have significant relevance to design and manufacturing communities. (C) 2010 Elsevier Ltd. All rights reserved.

Item Type: Journal Article
Subjects: T Technology > TA Engineering (General). Civil engineering (General)
T Technology > TN Mining engineering. Metallurgy
Divisions: Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH): Nonferrous metals, Nonferrous alloys, Aluminum -- Mechanical properties, Aluminum -- Welding
Journal or Publication Title: Materials & Design
Publisher: Elsevier Ltd
ISSN: 0264-1275
Official Date: April 2011
Volume: Volume 32
Number: Number 4
Number of Pages: 8
Page Range: pp. 2107-2114
Identification Number: 10.1016/j.matdes.2010.11.047
Status: Peer Reviewed
Publication Status: Published
Access rights to Published version: Restricted or Subscription Access
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URI: http://wrap.warwick.ac.uk/id/eprint/41540

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