Influence of fusion zone size and failure mode on mechanical performance of dissimilar resistance spot welds of AISI 1008 low carbon steel and DP600 advanced high strength steel

The work here addresses the investigation of the effect of the welding parameters (welding time, welding current and electrode force) on the overload failure mode and mechanical performance of dissimilar resistance spot welds between drawing quality special killed AISI 1008 low carbon steel and DP600 dual phase steel. Mechanical properties of spot welds are described in terms of failure mode, peak load and energy absorption during the quasi-static tensile-shear test. Three distinct failure modes were observed during the tensile-shear test: interfacial, pullout and partial thickness–partial pullout failure modes. Correlations among failure mode, welding parameters, weld physical attributes and weld mechanical performance are analyzed. Effect of expulsion on mechanical performance of welds is also investigated.