A correlation study of mechanical strength of resistance spot welding of AA5754 aluminium alloy

L Han, M Thornton, D Boomer, M Shergold - Journal of Materials …, 2011 - Elsevier
L Han, M Thornton, D Boomer, M Shergold
Journal of Materials Processing Technology, 2011Elsevier
AA5754 aluminium alloy was resistance spot welded (RSW) to produce 27 different joint
stack-ups with differing process parameters and corresponding weld quality. Quasi-static
joint strength was evaluated for three test geometries; lap-shear, coach-peel and cross-
tension. The results derived from over 1000 samples demonstrate various fundamental
relationships. For lap-shear strength, a strong relationship with weld nugget diameter was
observed; whilst discrete strength levels were found for coach-peel test geometry …
AA5754 aluminium alloy was resistance spot welded (RSW) to produce 27 different joint stack-ups with differing process parameters and corresponding weld quality. Quasi-static joint strength was evaluated for three test geometries; lap-shear, coach-peel and cross-tension. The results derived from over 1000 samples demonstrate various fundamental relationships. For lap-shear strength, a strong relationship with weld nugget diameter was observed; whilst discrete strength levels were found for coach-peel test geometry, depending on the governing metal thickness of the parent sheet for the various stack-ups. For cross-tension strength; there is a relationship with nugget diameter; but data are sensitive to nugget periphery defects. These fundamental relationships provide a set of generalised design guidelines for RSW of aluminium that will have significant relevance to manufacturing communities.
Elsevier
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