Fatigue life estimation of ultrasonic spot welded Mg alloy joints

Published on Oct 1, 2014in Materials & Design7.991
· DOI :10.1016/J.MATDES.2014.05.008
V.K. Patel13
Estimated H-index: 13
(RyeU: Ryerson University),
S.D. Bhole31
Estimated H-index: 31
(RyeU: Ryerson University),
Daolun Chen63
Estimated H-index: 63
(RyeU: Ryerson University)
Sources
Abstract
Abstract Lightweight magnesium alloys are increasingly used in automotive and other transportation industries for weight reduction and fuel efficiency improvement. The structural application of magnesium components requires proper welding and fatigue resistance to guarantee their durability and safety. The objective of this investigation was to identify failure mode and estimate fatigue life of ultrasonic spot welded (USWed) lap joints of an AZ31B-H24 magnesium alloy. It was observed that the solid-state USWed joints exhibited a superior fatigue life compared with other welding processes. Fatigue failure mode changed from interfacial failure to transverse-through-thickness crack growth with decreasing cyclic load level, depending on the welding energy. Fatigue crack initiation and propagation occurred from both the notch tip inside the faying surface and the edge of sonotrode indentation-footprints due to the presence of stress concentration. A life prediction model for the spot welded lap joints developed by Newman and Dowling was adopted to estimate the fatigue lives of the USWed magnesium alloy joints. The fatigue life estimation, based on the fatigue crack growth model with the global and local stress intensity factors as a function of kink length and the experimentally determined kink angle, agreed fairly well with the obtained experimental results.
📖 Papers frequently viewed together
References42
Newest
#1D.R. Ni (RyeU: Ryerson University)H-Index: 1
#2Daolun Chen (RyeU: Ryerson University)H-Index: 63
Last. Z.Y. Ma (CAS: Chinese Academy of Sciences)H-Index: 55
view all 4 authors...
A semi-solid processed (thixomolded) Mg–9Al–1Zn magnesium alloy (AZ91D) was subjected to friction stir welding (FSW), aiming at evaluating the weldability and fatigue property of the FSW joint. Microstructure analysis showed that a recystallized fine-grained microstructure was generated in the nugget zone (NZ) after FSW. The yield strength, ultimate tensile strength, and elongation of the FSW joint were obtained to be 192 MPa, 245 MPa, and 7.6%, respectively. Low-cycle fatigue tests showed that ...
Source
#1Harish Rao (UA: University of Alabama)H-Index: 11
#2R.I. Rodriguez (UA: University of Alabama)H-Index: 10
Last. Wei Yuan (Hitachi)H-Index: 18
view all 7 authors...
Abstract In this study, rare-earth containing ZEK100 magnesium alloy sheets were joined using friction stir spot welding. In order to determine the influence of welding parameters on lap-shear strength, overlap joints were created under various tool rotational rate and shoulder plunge depths. Relationships between the maximum lap-joint strength and key features of the weld including effective sheet thickness, interfacial hook width, and shoulder plunge depth were established. Based on the result...
Source
#1Hongxia Zhang (TUT: Taiyuan University of Technology)H-Index: 9
#2G.H. Wu (TUT: Taiyuan University of Technology)H-Index: 2
Last. Wenxian Wang (TUT: Taiyuan University of Technology)H-Index: 20
view all 6 authors...
Abstract The fatigue behavior of AZ31B magnesium alloy welded joint during high cycle fatigue test was investigated by infrared thermography. Five stages of superficial temperature evolution were observed: an initial temperature increase, a temperature decline, a temperature equilibrium, an abrupt temperature increase and a temperature drop after the failure. The theoretical models were formulated to explain the observed temperature evolution. The mean temperature decline caused by thermoelastic...
Source
#1Caroline AshH-Index: 12
#2Elizabeth CulottaH-Index: 17
Last. Sacha VignieriH-Index: 15
view all 7 authors...
[Changing Climates Special Issue Index][1] ![Figure][2] Wet to dry. Kenya's Lake Magadi, now alkaline and mostly dry, once teemed with freshwater fish; a core drilled here will reveal ancient climate swings. CREDIT: © STEVE BLOOM IMAGES/ALAMY Anthropogenic climate change is now a part of our reality. Even the most optimistic estimates of the effects of contemporary fossil fuel use suggest that mean global temperature will rise by a minimum of 2°C before the end of this century and that CO2 emiss...
Source
[Changing Climates Special Issue Index][1] Anticipating the future under the influence of climate change is one of the most important challenges of our time, and the topic of the special section in this issue of Science (see p. [472][2]). The natural systems that provide oxygen, clean water, food, storm and erosion protection, natural products, and the potential for future resources, such as new genetic stocks for cultivation, must be protected, not just because it is part of good stewardship bu...
Source
#1Jian Feng Nie (Monash University)H-Index: 62
#2Yuman Zhu (Monash University)H-Index: 25
Last. Xi-Ya Fang (Monash University)H-Index: 22
view all 4 authors...
The formability and mechanical properties of many engineering alloys are intimately related to the formation and growth of twins. Understanding the structure and chemistry of twin boundaries at the atomic scale is crucial if we are to properly tailor twins to achieve a new range of desired properties. We report an unusual phenomenon in magnesium alloys that until now was thought unlikely: the equilibrium segregation of solute atoms into patterns within fully coherent terraces of deformation twin...
Source
#1V.K. Patel (RyeU: Ryerson University)H-Index: 13
#2S.D. Bhole (RyeU: Ryerson University)H-Index: 31
Last. Daolun Chen (RyeU: Ryerson University)H-Index: 63
view all 3 authors...
Abstract The structural application of ultra-lightweight magnesium alloys inevitably involves welding and joining. A solid-state welding – ultrasonic spot welding (USW) – was conducted on AZ31B-H24 Mg alloy sheet by varying a key parameter of welding energy in this study, aiming to identify the changes in the microstructure, crystallographic texture, and lap shear tensile strength. The grain size was observed to increase with increasing welding energy. Crystallographic texture determined via X-r...
Source
#1B. S. Naik (RyeU: Ryerson University)H-Index: 3
#2Daolun Chen (RyeU: Ryerson University)H-Index: 63
Last. Priti Wanjara (National Research Council)H-Index: 19
view all 4 authors...
Friction stir welding (FSW), being an enabling solid-state joining technology, can be suitably applied for the assembly of lightweight magnesium (Mg) alloys. In this investigation, friction stir lap welded (FSLWed) joints of AZ31B-H24 Mg alloy were characterized in terms of the welding defects, microstructure, hardness, and fatigue properties at various combinations of tool rotational rates and welding speeds. It was observed that the hardness decreased from the base metal (BM) to the stir zone ...
Source
#1V.K. Patel (RyeU: Ryerson University)H-Index: 13
#2S.D. Bhole (RyeU: Ryerson University)H-Index: 31
Last. Daolun Chen (RyeU: Ryerson University)H-Index: 63
view all 3 authors...
Abstract Ultrasonic spot welding (USW) of AZ31B-H24 magnesium alloy sheet to high strength low alloy (HSLA) steel sheet with a zinc interlayer was successfully achieved. Thin layer of intermetallic compounds (IMCs) of Mg 7 Zn 3 , Mg 2 Zn 11 and MgZn 2 were present at the interface between magnesium and zinc substrate, while at the other interface (iron and zinc), no IMCs were found. A single crystal-like strong basal crystallographic texture in a zinc interlayer was identified. The (0 0 0 2) pea...
Source
#1Lei Liu (UW: University of Waterloo)H-Index: 24
#2L. Xiao (UW: University of Waterloo)H-Index: 5
Last. Y. Zhou (UW: University of Waterloo)H-Index: 64
view all 6 authors...
Abstract The structural application of lightweight magnesium alloys in the automotive industry inevitably involves dissimilar welding with steels and the related durability issues. This study was aimed at evaluating the microstructural change and fatigue resistance of Mg/steel resistance spot welds, in comparison with Mg/Mg welds. The microstructure of Mg/Mg spot welds can be divided into: base metal, heat affected zone and fusion zone (nugget). However, the microstructure of Mg/steel dissimilar...
Source
Cited By22
Newest
#1Felice RubinoH-Index: 13
#2Hetal Parmar (UNISA: University of Salerno)H-Index: 3
Last. Pierpaolo Carlone (UNISA: University of Salerno)H-Index: 24
view all 4 authors...
Solid-state welding processes have become the most integral development in the field of materials joining since its inception and have found widespread usage in many industries. In the past decade,...
Source
#1Vishal Naranje (Amity University)H-Index: 7
#2Sachin SalunkheH-Index: 4
The present work is concerned with fatigue life prediction of active components of deep drawing dies. Finite element analysis is performed, and S-N approach is used to evaluate the number of cycles of deep drawing die. Based on the available evaluated data (from FE analysis) and mathematical formulae, the ANN program is developed in the MATLAB, which is used to predict the fatigue life of active components of deep drawing dies. The developed ANN program achieved satisfactory results and verified...
Source
#1S.M.A.K. Mohammed (RyeU: Ryerson University)H-Index: 2
#2S.S. Dash (RyeU: Ryerson University)H-Index: 1
Last. Daolun Chen (RyeU: Ryerson University)H-Index: 63
view all 5 authors...
Abstract The present study is focused on the evaluation of microstructures, tensile lap shear strength and fatigue resistance of ultrasonic spot welded joints of lightweight AA 5182 aluminum alloy. The temperature quickly increased during ultrasonic spot welding (USW), with the peak temperature increasing with increasing welding energy. A “necklace”-like ultrafine structure occurred at the weld interface due to the presence of dynamic recrystallization. The tensile lap shear strength increased w...
Source
#1V.K. Patel (RyeU: Ryerson University)H-Index: 13
#2S.D. Bhole (RyeU: Ryerson University)H-Index: 31
Last. Z.Y. Ma (CAS: Chinese Academy of Sciences)H-Index: 55
view all 6 authors...
Dissimilar welding of 2024Al alloy to SiC/2009Al composite was conducted via solid-state ultrasonic spot welding technique. Defect-free sound spot welds were successfully achieved. SiCp particles were observed to migrate from the composite side to 2024Al side along with the interfacial interlocking during the intense high-frequency rubbing, which increased with increasing welding energy. The microhardness across the ultrasonic spot welded similar and dissimilar joints remained nearly constant. T...
Source
#1He PengH-Index: 4
#2Xianquan JiangH-Index: 6
Last. Daolun ChenH-Index: 63
view all 5 authors...
Lightweight structural applications of magnesium and aluminum alloys inevitably necessitate welding and joining, especially dissimilar welding between these alloys. The objective of this study was to examine the feasibility of joining ZEK100 Mg alloy to Al6022 alloy via ultrasonic spot welding, focusing on effects of welding energy. An interface diffusion layer consisting of α-Mg and Al12Mg17 eutectic structure was observed to form, with its thickness increased from ~0.5 µm to ~30 µm with increa...
Source
#1Roziq HimawanH-Index: 1
view all 4 authors...
Abstract To enhance a corrosion resistant of ferritic steel in reactor pressure vessel, stainless steel was used as a cladding. Bonding process between these two steels may result a inhomogenity either sub-clad crack or un-joined part. To ensure the integrity, effective inspection method is needed for this purpose. Therefore, in this study, an experiment of ultrasonic test for inspection of two bonding plate was performed. The objective of this study is to develop an effective method in predicti...
Source
#1Meng-Nan Feng (TJU: Tianjin University)H-Index: 3
#2Yao Chen (TJU: Tianjin University)H-Index: 1
Last. Zhen Luo (TJU: Tianjin University)H-Index: 23
view all 5 authors...
ABSTRACTMg/Al dissimilar joints with favourable static and dynamic mechanical properties were obtained utilising ultrasonic spot welding and ultrasonic spot weld bonding technology. The fatigue behaviour, fatigue failure mode, and typical fatigue fracture surface morphology of Mg/Al ultrasonic spot welding and ultrasonic spot weld bonding joints were compared and observed to get a better understanding of the fatigue failure mechanism. In general, the Mg/Al ultrasonic spot weld bonding joint exhi...
Source
#1Guanghan Wu (SJTU: Shanghai Jiao Tong University)H-Index: 4
#2Dayong Li (SJTU: Shanghai Jiao Tong University)H-Index: 19
Last. Weiqin Tang (SJTU: Shanghai Jiao Tong University)H-Index: 6
view all 8 authors...
Abstract Fatigue life prediction of advanced high strength steels (AHSS) spot welded joints is of great importance for autobody design with AHSS being increasingly used. In the present work, the fatigue failure behaviors of the DP780GI spot welded joints under the tensile shear (TS) and coach peel (CP) loading conditions are experimentally investigated and numerically modelled. Two failure modes, eyebrow failure and weld button pull out occur in the tests of TS joints, while only interfacial fra...
Source
#1Teresa J. Rinker (GM: General Motors)H-Index: 3
#2Jwo Pan (UM: University of Michigan)H-Index: 16
Abstract Global stress intensity factor solutions for welds with various widths in lap-shear specimens of magnesium alloy AZ31 and high-strength low-alloy steel sheets are developed using finite element analyses. Results are compared to and validated with the analytical solutions based on the beam bending theory and semi-infinite planes with connection. Analyses are also conducted using modified elastic constants with a bimaterial constant of zero for specimens with small kinked cracks. Results ...
Source
This website uses cookies.
We use cookies to improve your online experience. By continuing to use our website we assume you agree to the placement of these cookies.
To learn more, you can find in our Privacy Policy.