Journal of Applied Science and Engineering

Published by Tamkang University Press

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Mechanical Engineering

Marwah Sabah Fakhri1,2, Ahmed Al-Mukhtar3,4This email address is being protected from spambots. You need JavaScript enabled to view it., and Ibtihal A. Mahmood2

1Ministry of Higher Education and Scientific Research-Baghdad, Iraq

2University of Technology-Iraq, Mechanical Engineering Department, Baghdad, Iraq

3College of Engineering, Al-Hussain University College, Iraq

4Institute of Structural Mechanics, Bauhaus-Universität Weimar, Germany

 

 

Received: January 27, 2024
Accepted: July 22, 2024
Publication Date: September 25, 2024

 Copyright The Author(s). This is an open access article distributed under the terms of the Creative Commons Attribution License (CC BY 4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are cited.


Download Citation: ||https://doi.org/10.6180/jase.202507_28(7).0003  


For decades, resistance spot welding (RSW) between aluminum and copper has encountered difficulties; however, it remains essential for modern applications. Additionally, crack propagation and the stress intensity factor (SIF) of dissimilar RSW have not been extensively investigated. The welding parameters used for Al-Al joints were as follows: welding current, time, and electrode force were set at 14,000 Amps, 0.8 seconds, and 7,000 N, respectively. Conversely, for Al-Cu joints, 14,000 Amps, 1 second, and 8,800 N were determined. The similar joints exhibited an average weld nugget size of 6 mm, whereas the dissimilar joints had a nugget size of 5.2 mm. The tensile shear force was 690 N and 780 N for dissimilar and similar joints, respectively. Accordingly, the fatigue load, as a percentage of the tensile force, was utilized at 414 N and 468 N for Al-Cu and Al-Al, respectively. Finite Element Analysis (FEA) was employed to determine the SIF. The initial crack length was determined to be 0.1 mm. The numerical solution was then compared with theoretical solutions for the opening SIF-KI, such as the equations proposed by Pook and Zhang. The FEA results showed higher values of SIF compared to those from theoretical solutions. Additionally, crack propagation was investigated for both dissimilar and similar joints at a determined failure load. Cracks tended to develop close to the heat-affected zone (HAZ) around the weld nugget diameter (dn). SIF and crack path have been verified.

 


Keywords: Aluminum; Copper; Crack; Fracture; Resistance spot welding; Stress intensity factor


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