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2a4 Spot Weld Mech Prop
2a4 Spot Weld Mech Prop
Mechanical Properties
Learning Activities
Lesson Objectives 1. View Slides;
When you finish this lesson you will 2. Read Notes,
understand: 3. Listen to lecture
• Peel Chisel and Tensile Mechanical 4. Do on-line
testing techniques workbook
• Factors which effect performance in
these mechanical tests
• The importance of these test for part
design
Keywords
Peel Test, Chisel Test, Tensile Shear Test, Multiple Nugget Test,
Weld Bond Tensile Test, Coupon Dimensions, Weld Spacing,
Electrode Conditioning, Button Shape, Plastic Hinge
Mechanical Properties of Spot Welds
• Peel Tests
• Chisel Test
• Tensile Test
• Tensile Shear Ratios
• Torsion Test
• Impact Tests
• Fatigue Test
AWS Spec D8.9-97, 1997
AWS Spec D8.9-97, 1997
AWS Spec D8.9-97, 1997
AWS Spec D8.9-97, 1997
AWS Spec D8.9-97, 1997
AWS Spec D8.9-97, 1997
Dickinson, “Welding in Auto Industry,
AISI, 1981
AWS Spec D8.9-97, 1997
AWS Spec D8.9-97, 1997
Advantages of Peel Test
• Ease of Performance
• Low Cost
• Ability to use on Shop Floor as quality control test
Area = Energy
“Static Toughness”
Promotes Partial
Promotes Full
Nugget Failure
Nugget Pull-Out
Mechanical Properties of Spot Welds
• Peel Tests
• Chisel Test
• Tensile Test
• Tensile Shear Ratios
• Torsion Test
• Impact Tests
• Fatigue Test
Dickinson, “Welding in Auto Industry,
AISI, 1981
Weld Time Min. Nugget With Peel Test
Weld Current
Chisel Test Tends to Expose Nugget Closer to Fusion Line
Turn to the person sitting next to you and discuss (1 min.):
• Why do automotive manufactures prefer the chisel test on
the production line over the peel test?
Mechanical Properties of Spot Welds
• Peel Tests
• Chisel Test
• Tensile Test - Tensile Shear
• Tensile Shear Ratios
• Torsion Test
• Impact Tests
• Fatigue Test
Dickinson, “Welding in Auto Industry,
AISI, 1981
AWS Spec D8.9-97, 1997
Kraus, “A Practical Design approach…”
Welding Journal, Oct 1961
Dickinson, “Welding in Auto Industry,
AISI, 1981
Vanden Bossche, “Ultimate Strength and Failure Mode..”,
SAE paper 770214, Feb 1977
Dickinson, Republic Steel Corp Internal Document, 1978
Tensile Shear Test
Single Nugget Test – Tensile Shear
• Material Thickness
• Nugget Size (Current & Time)
• BM Strength
• Carbon Content
• BM Structure
• Coatings
• Hold Time
• Post Weld Furnace Treatment
• Test Temperature
• Test Cross Head Speed
Multiple Nugget Test – Tensile Shear
Weld Bonding (Nugget plus Adhesive)
Material Thickness – Tensile Shear
Nugget
Pullout
Increase BM Strength
Interfacial Failure
Relationship between
Nugget Dia and Strength
Current Not Current/Strength
Turn to the person sitting next to you and discuss (1 min.):
• What criteria do you suppose automotive and appliance
designers use when selecting the type of weld joint they will
recommend for their products? Think about the joint
designs in cars and appliances.
Base Metal Strength
• Solid Solution Strengthening
• Grain Refinement Through Special Processing
• Precipitation Strengthening
• Cold-work Strengthening
• Heat Treatment Strengthening (Hardening)
Effect of Carbon Content
Grain Refinement
Precipitation
30o
In Machine Q&T
> 0.2 % C Steels
Up to 300% benefit
Must be done correct
<0.2% Carbon
No Benefit
Impact
Non-uniform loading on
Outside welds causes
deviation
Fewer Welds
Adhesive Dominates