Akademska digitalna zbirka SLovenije - logo
E-viri
Celotno besedilo
Recenzirano Odprti dostop
  • Effect of Fe-Al intermetall...
    Walker, Luke; Avedissian, Nicholas; Vanderbilt, Craig; Paolini, Daniel; Zhang, Wei

    International journal of fatigue, October 2024, 2024-10-00, Letnik: 187
    Journal Article

    Display omitted •Dissimilar joints of aluminum to steel exhibited high static and fatigue properties.•A method was developed to compare fatigue properties of various dissimilar joints.•Static fracture energy was promising to predict the dissimilar joint fatigue property.•Stress intensity factors were used to explain the transition in fatigue failure mode.•High cycle fatigue was not strongly affected by brittle Fe-Al intermetallic layer. Lightweight structures made of aluminum alloys and high strength steels are increasingly used for improving vehicle fuel efficiency. One barrier for joining aluminum and steel is the formation of brittle Fe-Al intermetallics that can have deleterious effects on joint ductility and strength under static loading conditions. However, it is unclear how the intermetallics affect the joint fatigue properties. In this study, the effect of intermetallics on fatigue properties of dissimilar metal joints between a 6xxx aluminum alloy and a high-strength steel is investigated on welds created by ultrasonic interlayered resistance spot welding (Ulti-RSW). Joint efficiency calculations are used to normalize the peak load so the fatigue properties of Ulti-RSW are compared with a wide range of joining processes in the literature. During fatigue testing the failure mode transitions from interfacial or button pull-out failure during low cycle fatigue loading (below 100,000 cycles) to through-thickness failure during high cycle (above 100,000 cycles). Based on the stress intensity factors calculated using a simple 2D fracture mechanics model, the transition in failure mode is attributed to the plastic deformation near the notch tip. Overall, this study shows that the intermetallics have little effect on the high-cycle fatigue properties of dissimilar spot joints.