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<p>Cracking susceptibility is a complex issue which has been extensively investigated for decades using both experimental and theoretical methods. In this study, cracking susceptibility in dissimilar aluminum alloy resistance spot welding (RSW) joints was investigated using thermodynamic simulations for three material combinations of aluminum alloys: 2195/5A06, 2195/2A14 and 2195/2219. The susceptibility to cracking was predicted using the maximum |d<i>T</i>/d(<i>f</i><sub>S</sub>)<sup>1/2</sup>| up to (<i>f</i><sub>S</sub>)<sup>1/2</sup> = 1 as the crack susceptibility index. For each material combination, the hot cracking susceptibility (HCS) index values were calculated according to the Kou’s criterion. HCS curves and maps were constructed based on the calculation results. The predicted susceptibility followed the order: 2195/5A06 &gt; 2195/2219 &gt; 2195/2A14. Experimental results showed no obvious cracks in any of dissimilar Al alloys RSWed joints. In addition, factors such as cooling rate and residual stress may influence crack formation. Therefore, these factors should be considered to enhance the accuracy of the predictions for dissimilar Al alloy RSWed joints.</p>

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Prediction of cracking susceptibility of dissimilar aluminum alloy for resistance spot welded joints

  • 期刊论文

  • 发表日期：

    2026年1月25日

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  • Yue Yang,
  • Zhen Luo,
  • Yang Li,
  • Yu Zhang

摘要

Cracking susceptibility is a complex issue which has been extensively investigated for decades using both experimental and theoretical methods. In this study, cracking susceptibility in dissimilar aluminum alloy resistance spot welding (RSW) joints was investigated using thermodynamic simulations for three material combinations of aluminum alloys: 2195/5A06, 2195/2A14 and 2195/2219. The susceptibility to cracking was predicted using the maximum |dT/d(fS)1/2| up to (fS)1/2 = 1 as the crack susceptibility index. For each material combination, the hot cracking susceptibility (HCS) index values were calculated according to the Kou’s criterion. HCS curves and maps were constructed based on the calculation results. The predicted susceptibility followed the order: 2195/5A06 > 2195/2219 > 2195/2A14. Experimental results showed no obvious cracks in any of dissimilar Al alloys RSWed joints. In addition, factors such as cooling rate and residual stress may influence crack formation. Therefore, these factors should be considered to enhance the accuracy of the predictions for dissimilar Al alloy RSWed joints.