Uniaxial Tensile and Simple Shear Behavior of Resistance Spot-Welded Dual-Phase Steel Joints

Small test coupons were machined from single spot welds in a dual-phase steel (DP600) to investigate deformation and failure of weld joints in both tension and shear. Quasi-static () testing was conducted in a miniature tensile stage with a custom image acquisition system. Strain accumulation in each weld was analyzed where fracture occurred, which was typically outside the fusion zone. A few shear test coupons that failed in the fusion zone were found to have the same spheroidal defects noted in previous work, and thus, severely limited weld strength and ductility. A novel strain mapping method based upon digital image correlation was employed to generate two-dimensional deformation maps, from which local stress-strain curves to failure were computed. As an important first step toward incorporation of material models into weld simulations, a preliminary finite element analysis of a tension test successfully reproduced the experimental results with material models for the base, heat-affected, and fusion zone materials generated from prior work.