Abstract
[0001] This project developed methodology to create failure cards for aluminum resistance spotwelds using LS-DYNA, with a project objective to achieve reasonable accuracy (>90%). Rigorous testing and simulation activities were conducted while developing the methodology. The methodology includes mathematically fitting a failure model to match the test data efforts and deviation from the test data. Weld development and the testing process included weld schedule development through robustness testing and microhardness testing to study heat affected zones around the weld nugget properties. Welded coupons were cross-sectioned to analyze for cracks and porosity in the weld nugget. Eventually, lap shear, coach peel, and cross tension weld coupon testing was conducted.
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Recommended Citation
Kulkarni, Akshay Arthur; Carvalho de Moraes, Joao Felipe; Lakshmanan, Aaditya; Das, Sazol Kumar; Slabbert, Lily Ann; and Yeagappan, Ashwin, "Failure Characterization Of Aluminum Resistance Spotwelds Using Ls-Dyna & Developing Machine Learning Model To Predict Spotweld Failure Parameters And Test Results", Technical Disclosure Commons, (May 15, 2025)
https://www.tdcommons.org/dpubs_series/8131