Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones
Accurately predicting the fatigue behavior of spot welds remains challenging due to varying material properties across weld zones. This study investigates the fatigue behavior of spot welds in DC04 steel through experimental testing and finite element modeling (FEM). Four modeling approaches—Solid E...
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| Language: | English |
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Elsevier
2025-03-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425001164 |
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| author | Hossein Aliyari Reza Miresmaeili Mohammad Azadi |
| author_facet | Hossein Aliyari Reza Miresmaeili Mohammad Azadi |
| author_sort | Hossein Aliyari |
| collection | DOAJ |
| description | Accurately predicting the fatigue behavior of spot welds remains challenging due to varying material properties across weld zones. This study investigates the fatigue behavior of spot welds in DC04 steel through experimental testing and finite element modeling (FEM). Four modeling approaches—Solid Element (SE), MPC Beam Element (MBE), Quad RBE3, and Triangular RBE3 Elements (T-RE)—were used to simulate the weld nugget, with material properties of the base metal (BM), heat-affected zone (HAZ), and fusion zone (FZ) characterized using a novel indentation method. Fatigue life predictions were conducted using multiaxial criteria, including Morrow, Brown-Miller-Morrow (BMM), and Smith-Watson-Topper (SWT). Microhardness and microstructural analyses identified a decarburized ''pale halo line'' at the FZ/HAZ interface, resulting in a notable reduction in hardness. Experimental fatigue tests validated the numerical models, with simulations using SE providing the most accurate predictions of fatigue life and fracture behavior. Among the fatigue criteria, BMM predictions were the most conservative, while Morrow and SWT showed closer agreement at higher stress levels. This research highlights the effectiveness of advanced modeling and material characterization techniques in improving the accuracy of fatigue life predictions for spot welds in the automotive industry. |
| format | Article |
| id | doaj-art-7aa080c936dc45afaa27eb4106116547 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-7aa080c936dc45afaa27eb41061165472025-01-29T05:01:21ZengElsevierJournal of Materials Research and Technology2238-78542025-03-013520872102Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zonesHossein Aliyari0Reza Miresmaeili1Mohammad Azadi2Department of Materials Engineering, Tarbiat Modares University, P.O. Box: 14115-143, Tehran, IranDepartment of Materials Engineering, Tarbiat Modares University, P.O. Box: 14115-143, Tehran, Iran; Corresponding author.Faculty of Mechanical Engineering, Semnan University, Semnan, IranAccurately predicting the fatigue behavior of spot welds remains challenging due to varying material properties across weld zones. This study investigates the fatigue behavior of spot welds in DC04 steel through experimental testing and finite element modeling (FEM). Four modeling approaches—Solid Element (SE), MPC Beam Element (MBE), Quad RBE3, and Triangular RBE3 Elements (T-RE)—were used to simulate the weld nugget, with material properties of the base metal (BM), heat-affected zone (HAZ), and fusion zone (FZ) characterized using a novel indentation method. Fatigue life predictions were conducted using multiaxial criteria, including Morrow, Brown-Miller-Morrow (BMM), and Smith-Watson-Topper (SWT). Microhardness and microstructural analyses identified a decarburized ''pale halo line'' at the FZ/HAZ interface, resulting in a notable reduction in hardness. Experimental fatigue tests validated the numerical models, with simulations using SE providing the most accurate predictions of fatigue life and fracture behavior. Among the fatigue criteria, BMM predictions were the most conservative, while Morrow and SWT showed closer agreement at higher stress levels. This research highlights the effectiveness of advanced modeling and material characterization techniques in improving the accuracy of fatigue life predictions for spot welds in the automotive industry.http://www.sciencedirect.com/science/article/pii/S2238785425001164Resistance spot welding (RSW)Heat-affected zone (HAZ)MicroindentationFatigue life estimationFinite element simulation |
| spellingShingle | Hossein Aliyari Reza Miresmaeili Mohammad Azadi Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones Journal of Materials Research and Technology Resistance spot welding (RSW) Heat-affected zone (HAZ) Microindentation Fatigue life estimation Finite element simulation |
| title | Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones |
| title_full | Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones |
| title_fullStr | Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones |
| title_full_unstemmed | Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones |
| title_short | Fatigue life prediction of spot-welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones |
| title_sort | fatigue life prediction of spot welded joints using a novel indentation technique for precise elastoplastic characterization of weld zones |
| topic | Resistance spot welding (RSW) Heat-affected zone (HAZ) Microindentation Fatigue life estimation Finite element simulation |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425001164 |
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