Failure Mechanisms of Advanced Welding Processes

329 Pages·2010·6.52 MB·English

by  X. Sun

Failure mechanisms of advanced welding processes
© Woodhead Publishing Limited, 2010
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© Woodhead Publishing Limited, 2010
Failure mechanisms
of advanced
welding processes
Edited by
Xin Sun
Oxford Cambridge New Delhi
© Woodhead Publishing Limited, 2010
Published by Woodhead Publishing Limited, Abington Hall, Granta Park, Great
Abington, Cambridge CB21 6AH, UK
www.woodheadpublishing.com
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© Woodhead Publishing Limited, 2010
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© Woodhead Publishing Limited, 2010
Contents
Contributor contact details ix
1 Mechanics modeling of spot welds under general
loading conditions and applications to fatigue life
predictions 1
J. Pan and K. Sripichai, University of Michigan, USA,
P-C. Lin, National Chung Cheng University, Taiwan,
D-A. Wang, National Chung Hsing University, Taiwan,
and S-H. Lin, SuperAlloy Industrial Co. Ltd., Taiwan
1.1 Introduction 1
1.2 Spot weld in a fi nite plate under general loading
conditions 3
1.3 Closed-form solutions for a plate with an inclusion 5
1.4 Stress intensity factor solutions for a strip under various
types of loading conditions 5
1.5 Kinked fatigue crack model for spot welds 11
1.6 Life predictions for spot welds in lap-shear specimens 17
1.7 Conclusions 19
1.8 Acknowledgements 21
1.9 References 21
2 Resistance spot weld failure mode and weld
performance for aluminum alloys 24
X. Sun, Pacifi c Northwest National Laboratory, USA
2.1 Introduction 24
2.2 Experimental study of aluminum spot welds 27
2.3 Statistical data analysis for aluminum spot welds 29
2.4 Analytical failure mode prediction for aluminum spot
welds under cross tension loading condition 33
2.5 Model validation and discussion of aluminum spot welds 36
v
© Woodhead Publishing Limited, 2010
vi Contents
2.6 Conclusions 40
2.7 References 41
3 Resistance spot weld performance and weld failure
modes for dual phase and TRIP steels 43
M. Tumuluru, United States Steel Corporation, USA
3.1 Introduction 43
3.2 Method of production and microstructure of steels 45
3.3 Resistance spot welding behavior 45
3.4 Weld failure modes 52
3.5 Future trends 61
3.6 Summary 62
3.7 References 63
4 Fatigue behavior of spot welded joints in steel sheets 65
S. K. Khanna, University of Missouri, USA, and
X. Long, Center for Reliable Energy Systems, USA
4.1 Introduction 65
4.2 Experimental study of fatigue behavior of spot welds 67
4.3 Micro-hardness measurements in spot welds 71
4.4 Fracture modes and microstructure in spot welds 72
4.5 Random loading fatigue test in spot welds 77
4.6 Effect of residual stress on fatigue behavior of spot
welded joints 79
4.7 Models for fatigue life prediction of spot welded joints 84
4.8 Fatigue life assessment approaches for spot welds 86
4.9 Current status of fatigue life prediction of welded
materials or structures 90
4.10 Conclusions 94
4.11 Acknowledgements 95
4.12 References 95
5 Non-destructive evaluation of spot-weld quality 101
B. Ghaffari, Ford Motor Company, USA, and
G. Mozurkewich, Ford Motor Company (retired), USA
5.1 Introduction 101
5.2 Background 103
5.3 Techniques for non-destructive evaluation of spot welds 106
5.4 Single-element ultrasonic inspection 108
5.5 Ultrasonic imaging 116
5.6 Additional materials and welding techniques 123
5.7 In-process ultrasonic monitoring 125
5.8 History and future trends 127
© Woodhead Publishing Limited, 2010
Contents vii
5.9 Conclusions 129
5.10 References 131
6 Solid state joining: fundamentals of friction stir
welding 137
K. J. Colligan, Concurrent Technologies Corporation,
USA
6.1 Overview of process principles 137
6.2 Comparison to other welding processes 142
6.3 Welding tools 149
6.4 Parameter effects 153
6.5 Materials 154
6.6 Joint geometries 156
6.7 References 160
7 Failure mechanisms in friction stir welds 164
M. N. James, University of Plymouth, UK, and
D. G. Hattingh, H. Lombard, I. Wedderburn,
D. L. H. Bulbring, and A. Els-Botes, Nelson Mandela
Metropolitan University, South Africa, and A. Steuwer,
ESS Scandinavia, Sweden
7.1 Introduction 164
7.2 Defects in linear friction stir welds 165
7.3 Crack paths in tensile and fatigue fracture 175
7.4 Friction taper stud welding 179
7.5 Friction stir spot welds 182
7.6 Residual stresses in friction stir welds 183
7.7 Conclusions 184
7.8 Acknowledgements 186
7.9 References 186
8 Microstructure characteristics and mechanical
properties of the magnesium and aluminium alloy
laser weld bonded joint 190
L. Liu, Dalian University of Technology, China
8.1 Introduction of laser weld bonding technique 190
8.2 Laser weld bonding process 192
8.3 Microstructure analyses of laser weld bonded Mg to Al
joint 200
8.4 Mechanical properties of laser weld bonded Mg to Al
joint 212
8.5 Future trends 215
8.6 References 216
© Woodhead Publishing Limited, 2010
viii Contents
9 Fatigue in laser welds 218
V. Caccese, University of Maine, USA
9.1 Introduction 218
9.2 Methods of laser welding 219
9.3 Applications of laser welding 223
9.4 Future trends in laser welding 224
9.5 Properties of laser welded materials 226
9.6 Fatigue life prediction in welded joints 230
9.7 Fatigue tests of laser welded specimens 235
9.8 Conclusions 251
9.9 References 253
10 Weld metal ductility and its infl uence on formability
of tailor welded blanks 258
A. A. Zadpoor, Materials Innovation Institute (M2i) and
J. Sinke, Delft University of Technology, The Netherlands
10.1 Introduction 258
10.2 Mechanical properties of tailor welded blanks 261
10.3 Formability of tailor welded blanks 267
10.4 Formability prediction for tailor welded blanks 275
10.5 Concluding remarks 282
10.6 Future trends 283
10.7 Sources of further information and advice 283
10.8 Acknowledgements 284
10.9 References 284
11 Joining lightweight materials using reactive
nanofoils 289
X. Sun, Pacifi c Northwest National Laboratory, USA
11.1 Introduction 289
11.2 Joint population defi nition and fabrication 291
11.3 Results 291
11.4 Comparison with automotive adhesive bonds 304
11.5 Conclusions and discussion 305
11.6 References 305
Index 307
© Woodhead Publishing Limited, 2010
Contributor contact details
(* = main contact) D-A. Wang
Institute of Precision Engineering
National Chung Hsing University
Taichung
Editor, Chapter 2 and 11 Taiwan
X. Sun*
S-H. Lin
Pacifi c Northwest National
Wheel Group
Laboratory
SuperAlloy Industrial Co. Ltd.
902 Battelle Blvd.
Yun-Lin 640
Richland, WA 99352
Taiwan
USA
E-mail: [email protected] Chapter 3
Chapter 1 M. Tumuluru
United States Steel Corporation
J. Pan* and K. Sripichai
Research and Technology Center
Mechanical Engineering
800 East Waterfront Drive
University of Michigan
Munhall, PA 15120
Ann Arbor, MI 48109
USA
USA
E-mail: [email protected]
E-mail: [email protected]
[email protected]
P-C. Lin
Mechanical Engineering
National Chung Cheng University
Chia-Yi 621
Taiwan
E-mail: [email protected]
ix
© Woodhead Publishing Limited, 2010