PSI - Issue 51

ScienceDirect Structural Integrity Procedia 00 (2022) 000–000 Structural Integrity Procedia 00 (2022) 000–000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 51 (2023) 102–108

© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ICSID 2022 Organizers Abstract Responding to the increasing demand of multi-material solutions for structural lightweighting in automotive industry, resistance spot welding (RSW) of two sheets, e.g. aluminum to aluminum, or aluminum to steel, has been successfully developed and implemented in production using novel multi-ring domed (MRD) electrodes and multiple solidification weld schedules. In this study, we report, for the first time, the successful RSW of three sheets, i.e. 1.2 mm thick AA6022 to 0.65 mm thick high strength low alloy (HSLA) steel and 1.4 mm thick CR780T steel sheets. The resultant RSWs formed a thin layer of intermetallic compound between the aluminum-steel interface and a much smaller but completely melted weld nugget between the two steels, achieving an acceptable joint strength com-pared to RSWs of 1.2 mm thick AA6022 to itself and 1.2 mm thick AA6022 to 2.0 mm thick HSLA. Fatigue test results show that the three-sheet RSWs reached comparable fatigue behavior to that of 1.2 mm AA6022 to 2.0 mm HSLA. Using the structural stress analysis, all the fatigue data fall onto one master curve indicating that the aluminum-steel weld nugget diameter dominates the fatigue life. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ICSID 2022 Organizers Keywords: Three-sheet aluminum-steel-steel resistance spot welds; intermetallic compound; fatigue behavior; structural stress analysis 6th International Conference on Structural Integrity and Durability (ICSID 2022) Fatigue behavior of three-sheet aluminum-steel dissimilar resistance spot welds for automotive applications Liting Shi a,b , Jia Xue b , Jidong Kang b,* , Amberlee S. Haselhuhn c , Hassan Ghassemi-Armaki c , Blair E. Carlson c a Zhejiang Provincial Engineering Center of Integrated Manufacturing Technology and Intelligent Equipment, Hangzhou City University, Hangzhou, Zhejiang 310015, China b CanmetMATERIALS, 183 Longwood Road South, Hamilton, ON L8P 0A5, Canada c General Motors Global R&D Center, 30470 Harley Earl Blvd, Warren, MI 48092, U.S.A. Abstract Responding to the increasing demand of multi-material solutions for structural lightweighting in automotive industry, resistance spot welding (RSW) of two sheets, e.g. aluminum to aluminum, or aluminum to steel, has been successfully developed and implemented in production using novel multi-ring domed (MRD) electrodes and multiple solidification weld schedules. In this study, we report, for the first time, the successful RSW of three sheets, i.e. 1.2 mm thick AA6022 to 0.65 mm thick high strength low alloy (HSLA) steel and 1.4 mm thick CR780T steel sheets. The resultant RSWs formed a thin layer of intermetallic compound between the aluminum-steel interface and a much smaller but completely melted weld nugget between the two steels, achieving an acceptable joint strength com-pared to RSWs of 1.2 mm thick AA6022 to itself and 1.2 mm thick AA6022 to 2.0 mm thick HSLA. Fatigue test results show that the three-sheet RSWs reached comparable fatigue behavior to that of 1.2 mm AA6022 to 2.0 mm HSLA. Using the structural stress analysis, all the fatigue data fall onto one master curve indicating that the aluminum-steel weld nugget diameter dominates the fatigue life. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ICSID 2022 Organizers Keywords: Three-sheet aluminum-steel-steel resistance spot welds; intermetallic compound; fatigue behavior; structural stress analysis 6th International Conference on Structural Integrity and Durability (ICSID 2022) Fatigue behavior of three-sheet aluminum-steel dissimilar resistance spot welds for automotive applications Liting Shi a,b , Jia Xue b , Jidong Kang b,* , Amberlee S. Haselhuhn c , Hassan Ghassemi-Armaki c , Blair E. Carlson c a Zhejiang Provincial Engineering Center of Integrated Manufacturing Technology and Intelligent Equipment, Hangzhou City University, Hangzhou, Zhejiang 310015, China b CanmetMATERIALS, 183 Longwood Road South, Hamilton, ON L8P 0A5, Canada c General Motors Global R&D Center, 30470 Harley Earl Blvd, Warren, MI 48092, U.S.A.

__________ * Corresponding author. Tel.: +001 905-518-1534 ; fax: +001 905-645-0831. E-mail address : jidong.kang@nrcan-rncan.gc.ca __________ * Corresponding author. Tel.: +001 905-518-1534 ; fax: +001 905-645-0831. E-mail address : jidong.kang@nrcan-rncan.gc.ca

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ICSID 2022 Organizers 2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ICSID 2022 Organizers

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ICSID 2022 Organizers 10.1016/j.prostr.2023.10.074