Predicting the Failure of Ultrasonic Spot Welds by Pull-out from Sheet Metal

Bin Zhou, M. D. Thouless, and S. M. Ward Department of Mechanical Engineering Department of Material Science and Engineering University of Michigan Ann Arbor, MI, 48109 Scientific Research Laboratory Ford Motor Company Dearborn, MI, 48124 Abstract A methodology for determining the cohesive facture parameters associated with pull-out of spot welds is presented. Since failure of a spot weld by pull-out occurs by mixed-mode fracture of the base metal, the cohesive parameters for ductile fracture of an aluminum alloy were determined and then used to predict the failure of two very different spot-welded geometries. The fracture parameters (characteristic strength and toughness) associated with the shear and normal modes of ductile fracture in thin aluminum alloy coupons were determined by comparing experimental observations to numerical simulations in which a cohesive-fracture zone was embedded within a continuum representation of the sheet metal. These parameters were then used to predict the loaddisplacement curves for ultrasonically spot-welded joints in T-peel and lap-shear configurations. The predictions were in excellent agreement with the experimental data. The results of the present work indicate that cohesive-zone models may be very useful for design purposes, since both the strength and the energy absorbed by plastic deformation during weld pull-out can be predicted quite accurately.