Multi-scale mechanical modeling of Al-steel resistance spot welds

• Published in: Materials science & engineering. A, Structural materials : properties, microstructure and processing Structural materials : properties, microstructure and processing, 2018-09, Vol.735 (C), p.145-153
• Main Authors: Chen, Jian, Feng, Zhili, Wang, Hui-Ping, Carlson, Blair E., Brown, Tyson, Sigler, David
• Format: Article
• Language: English
• Subjects: Al-steel resistance spot welds; Computer simulation; Deformation and fracture; Deformation resistance; Finite element analysis; Finite element method; Finite element modeling; Intermetallic compound; Intermetallic compounds; MATERIALS SCIENCE; Mathematical analysis; Mathematical models; Mechanical properties; Morphology; Multiscale analysis; Predictions; Scale models; Shear strength; Spot welds; Steel alloys; Tension tests; Thickness; Three dimensional models; Welded joints
• ISSN: 0921-5093; 1873-4936
• DOI: 10.1016/j.msea.2018.08.039

A multi-scale finite element modeling approach was developed to study the deformation and fracture behavior of Al-steel resistance spot welds. First, a micro-scale model was applied to simulate the mechanical responses of the intermetallic compound (IMC) layer having various morphologies and thicknesses under tensile and shear loading conditions. Second, the predicted tensile and shear strength of the IMC layer, that varied along the joint interface per the IMC layer morphology and thickness variation, was then introduced into 3D macro-scale models to predict the overall mechanical performance of weld coupons under coach peel, lap shear and cross-tension testing conditions. The numerical predictions agreed reasonably well with the experimental data.