| Although aluminum materials have proven to be a possible weight saving solution, the strength of Al joints remains a challenge in auto industry. Improving the mechanical properties of resistance spot welding, as a major joining method, has been the subject of numerous studies. However, the effects of forging on the mechanical properties of Al spot-welded joints had not been yet determined.; Systematic tensile/fatigue tests and microstructural characterization were conducted on three sets of aluminum DC single-phase spot-welds. The results showed an enhancement in the fatigue life as the result of forging. Crack initiation occurred out of the weld pool in the heat affected zone at the end of the notch, where the stress concentration is highest. No correlation was detected between fatigue life and weld pool microstructure. Residual stress analysis on the weld pool and its vicinity is recommended to clarify if forging impacts the residual stress relieving mechanism. |
