Tensile shear fracture load bearing capability, softening of HAZ and microstructural characteristics of resistance spot welded DP-1000 steel joints

Paluchamy Rajalingam; Selvarajan Rajakumar; Visvalingam Balasubramanian; Tushar Sonar; Subramanian Kavitha

doi:10.1515/mt-2022-0236

Article

Tensile shear fracture load bearing capability, softening of HAZ and microstructural characteristics of resistance spot welded DP-1000 steel joints

Paluchamy Rajalingam
Paluchamy Rajalingam is working as a Senior technical trainer in Dubai. He is completing his PhD Manufacturing Engineering (Welding) from Annamalai University. He completed his M.E. (Manufacturing Engineering) from Anna University and B.E (Mechanical Engineering) from JRNRV University. He has a total of 3 years of work experience in research and one year of teaching. His research interests include different welding, advanced materials for Automobile application.
, Selvarajan Rajakumar
Selvarajan Rajakumar is working currently as Associate Professor from Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, India. He completed his graduation (Mechanical and Production Engineering), post-graduation (Production Engineering) and PhD (Production Engineering) from Annamalai University, Chidambaram. He has 18 years of teaching experience and 15 years of research experience. He has published more than 60 papers in SCOPUS indexed Journals and his ‘h’ index is 20. He has supervised 3 PhD scholars and guiding 6 more scholars. He has completed 8 R & D projects worth of Rs. 1.5 crores from various funding agencies. His areas of interest are Materials Joining, Surface Engineering and Optimization.
, Visvalingam Balasubramanian
Visvalingam Balasubramanian is working as Director for Directorate of Research and Development (DRD) in Annamalai University. He is Professor and Director of Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University. He has h-index of 52 and is included in top 2% scientist list in materials by Stanford University, USA. He graduated from Government College of Engineering, Salem, University of Madras, in 1989 and obtained his post-graduation from College of Engineering Guindy, Anna University, Chennai, in 1992. He obtained his PhD from Indian Institute of Technology Madras (IITM), Chennai, in 2000. He has 28 years of teaching and 25 years of research experience. He has published 420 research papers in international journals and supervised 22 PhD scholars. His areas of interest are Materials Joining, Surface Engineering and Nanomaterials.
, Tushar Sonar
Tushar Sonar is working as a Senior Research Scientist at Department of Welding Engineering, Institution of Engineering and Technology, South Ural State University, Chelyabinsk, Russia. He completed his PhD Manufacturing Engineering (Welding) from Annamalai University in the year 2021. He completed his M.Tech. (Mechanical Engineering) from Dr. Babasaheb Ambedkar Marathwada University, Aurangabad in the year 2016 and B.E (Mechanical Engineering) from Pune University in the year 2013. He is a recipient of the ISRO RESPOND research fellowship. He has published 40 research papers in reputed international journals, 8 papers in national journals and presented 17 research papers at international conferences. He has more than 6 years of work experience including teaching, industry, and research. His research interests include Welding and Additive Manufacturing.
and Subramanian Kavitha
Subramanian Kavitha is working as Assistant Professor, Department of Electronics and Instrumentation Engineering, NPMaSS National MEMS Design Centre, Annamalai University, Annamalai Nagar. She completed her graduation (Electronics and Instrumentation Engineering) and post-graduation (Process Control and Instrumentation Engineering) from Annamalai University in 1997 and 2002 respectively. She obtained her PhD (Microelectronics and MEMS) from Annamalai University in 2015. She has a total of 18 years of teaching experience, 1 year of industrial experience and 10 years of research experience. She has completed 4 R&D projects worth of Rs. 68 lakhs from various funding agencies like DST, AICTE and UGC. Her areas of research interests are Microelectronics and MEMS, Structural Health Monitoring and IoT. She received ‘Best Researcher Grant Award’ from Annamalai University in the year of 2017.

Published/Copyright: January 9, 2023

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From the journal Materials Testing Volume 65 Issue 1

Abstract

The main objective of this investigation is to enhance the tensile shear fracture load (TSFL) bearing capability and minimize softening in heat affected zone (HAZ) of resistance spot welded DP-1000 steel spot joints for automotive applications. The lap tensile and cross tensile shear fracture load tests (LTSFL and CTSFL) were conducted. The process parameters were optimized using numerical and graphical optimization techniques to maximize the TSFL capability of spot joints. The microstructure of spot joints was studied using optical microscopy and correlated to TSFL and hardness of spot joints. Results showed that DP-1000 steel spot joints made using the welding power of 70 W, welding time of 1.0 s, electrode pressure of 4.25 MPa showed maximum LTSFL of 22 kN and CTSFL of 9.1 kN. The parametric optimization showed 46.66, 45.77, 22.33 and 9.87% increase in LTSFL, CTSFL, nugget zone hardness and HAZ hardness of DP-1000 steel spot joints. The higher TSFL and nugget hardness of spot joints is mainly attributed to the evolution of finer martensitic sandwiching ferrite phases in nugget zone and lower softening of HAZ than other joints. Welding power showed significant influence on TSFL of spot joints followed by welding time and electrode pressure.

Keywords: DP-1000 steel; hardness; microstructure; resistance spot welding; softening of HAZ; tensile shear fracture load

Corresponding author: Selvarajan Rajakumar, Mechanical Engineering, Annamalai University, Annamalai Nagar 608002, Tamil Nadu, India; and Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Chidambaram 608002, Tamil Nadu, India, Email: srkcemajor@yahoo.com

About the authors

Paluchamy Rajalingam

Paluchamy Rajalingam is working as a Senior technical trainer in Dubai. He is completing his PhD Manufacturing Engineering (Welding) from Annamalai University. He completed his M.E. (Manufacturing Engineering) from Anna University and B.E (Mechanical Engineering) from JRNRV University. He has a total of 3 years of work experience in research and one year of teaching. His research interests include different welding, advanced materials for Automobile application.

Selvarajan Rajakumar

Selvarajan Rajakumar is working currently as Associate Professor from Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, India. He completed his graduation (Mechanical and Production Engineering), post-graduation (Production Engineering) and PhD (Production Engineering) from Annamalai University, Chidambaram. He has 18 years of teaching experience and 15 years of research experience. He has published more than 60 papers in SCOPUS indexed Journals and his ‘h’ index is 20. He has supervised 3 PhD scholars and guiding 6 more scholars. He has completed 8 R & D projects worth of Rs. 1.5 crores from various funding agencies. His areas of interest are Materials Joining, Surface Engineering and Optimization.

Visvalingam Balasubramanian

Visvalingam Balasubramanian is working as Director for Directorate of Research and Development (DRD) in Annamalai University. He is Professor and Director of Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University. He has h-index of 52 and is included in top 2% scientist list in materials by Stanford University, USA. He graduated from Government College of Engineering, Salem, University of Madras, in 1989 and obtained his post-graduation from College of Engineering Guindy, Anna University, Chennai, in 1992. He obtained his PhD from Indian Institute of Technology Madras (IITM), Chennai, in 2000. He has 28 years of teaching and 25 years of research experience. He has published 420 research papers in international journals and supervised 22 PhD scholars. His areas of interest are Materials Joining, Surface Engineering and Nanomaterials.

Tushar Sonar

Tushar Sonar is working as a Senior Research Scientist at Department of Welding Engineering, Institution of Engineering and Technology, South Ural State University, Chelyabinsk, Russia. He completed his PhD Manufacturing Engineering (Welding) from Annamalai University in the year 2021. He completed his M.Tech. (Mechanical Engineering) from Dr. Babasaheb Ambedkar Marathwada University, Aurangabad in the year 2016 and B.E (Mechanical Engineering) from Pune University in the year 2013. He is a recipient of the ISRO RESPOND research fellowship. He has published 40 research papers in reputed international journals, 8 papers in national journals and presented 17 research papers at international conferences. He has more than 6 years of work experience including teaching, industry, and research. His research interests include Welding and Additive Manufacturing.

Subramanian Kavitha

Subramanian Kavitha is working as Assistant Professor, Department of Electronics and Instrumentation Engineering, NPMaSS National MEMS Design Centre, Annamalai University, Annamalai Nagar. She completed her graduation (Electronics and Instrumentation Engineering) and post-graduation (Process Control and Instrumentation Engineering) from Annamalai University in 1997 and 2002 respectively. She obtained her PhD (Microelectronics and MEMS) from Annamalai University in 2015. She has a total of 18 years of teaching experience, 1 year of industrial experience and 10 years of research experience. She has completed 4 R&D projects worth of Rs. 68 lakhs from various funding agencies like DST, AICTE and UGC. Her areas of research interests are Microelectronics and MEMS, Structural Health Monitoring and IoT. She received ‘Best Researcher Grant Award’ from Annamalai University in the year of 2017.

Acknowledgement

The authors express sincere gratitude to Director, Centre for Materials Joining and Research, CEMAJOR, Annamalai University, Annamalai Nagar, Tamil Nadu State, India, for providing the resistance spot welding and materials testing facilities.

Author contribution: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
Research funding: None declared.
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

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Published Online: 2023-01-09

Published in Print: 2023-01-27

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Articles in the same Issue

https://doi.org/10.1515/mt-2022-0236

Keywords for this article

DP-1000 steel; hardness; microstructure; resistance spot welding; softening of HAZ; tensile shear fracture load