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Dual phase steel DP980 sheets were joined by resistance spot welding (RSW) process. Mechanical resistance of the welds was characterized by microhardness, tensile shear and fatigue tests. A significant hardness decreases was observed in the RSW lap joints with respect to the base material, which was attributed to phase transformations during the heating and cooling of the steel. Fatigue Wohler curves using a fixed load ratio of 0.1 were obtained. It was found that the spot weld at the nugget interface close to the fusion zone induced a critical stress concentration factor, which decreased the fatigue life of the joints in the as-welded condition. Failure of the welds was initiated at the interface between welded sheets. Two predominant fatigue fracture modes were observed associated with mode I/III cyclic loading, which were correlated with the fatigue crack initiation and propagation stages. Compressive residual stresses were induced by a loading-unloading cycle on the spot welds, which tends to increase the fatigue life of the joints when compared to the as-welded condition.

The influence of variable load spectra in the fatigue crack growth (FCG) was analyzed. A 4.1% interference was pre-set to some specimens by an expansion operation. As-drilled hole and hole expanded specimens were subjected to FCG tests under a combination of baseline cyclic loading and periodic overloads or underloads applied. Fatigue life was of approximately 1 million of cycles for the as-drilled hole, and 3.5 million of cycles for the hole cold expanded. The pre-setting operation and variable load spectra interaction exhibited a synergy, which was associated with multiple periods of retardation and arresting observed in the crack growth rate.