Microstructural and interface geometrical influence on the mechanical fatigue property of aluminum/high-strength steel lap joints using resistance element welding for lightweight vehicles: experimental and computational investigation

The present study investigates a fatigue property and its microstructural and interface geometrical effect on the resistance element welded (REWed) aluminum (Al)/high-strength steel (Fe) lap joint. The assembled Al/Fe joints were subjected under the fatigue strength up to 80% of tensile-shear loads with 0.1 of the load ratio. As a result, an exceptional fatigue strength has been secured inducing the base material fracture because there are no noticeable interfacial defects at the 10.5 kA welding condition compared to assemblies joined with 3.5–4.5 kA of welding currents. Even, maximum tensile-shear loads exceed 9 kN at the 10.5 kA welding condition. Microstructural developments of base materials and welding interfaces were thoroughly analyzed by an optical microscopy (OM) and electron backscatter diffraction (EBSD), the development of prior-austenite-grain-boundaries (PAGBs) and α'-martensite phases were observed in the welding interfaces at all conditions. Heat affected zone (HAZ) developments of AA5052 were quantitatively analyzed in terms of recrystallization and grain growth, providing significant differences in the fatigue performances and striation, crack propagation developments. In addition, with the help of a finite element (FE) computational modeling, a mechanical stress distribution and strain behavior by geometries of the joining interface are discussed in detail.