Possible failure modes for spot welds

A spot welded joint can have two fundamentally different types of failure modes. The first failure modes can occur due to cracking of one of the sheet metals, which are connected by the spot weld. The other possible failure mode is crack propagation through the weld nugget. [1].

Failure Mode "Cracking in the Sheet Metal" and Crack Patterns, According to [6] in the Bibliography

Experimental studies performed by Rupp et al. [3] show that the main influencing parameter, which determines the resulting failure mode, is the ratio of the weld nugget diameter d to the sheet thickness t. The study has shown that following rule-of-thumb is valid for identifying the limiting condition at which the failure mode "Cracking through the weld nugget" occurs.

In other words, when the diameter of the weld nugget is greater than , the failure mode "Cracking in the sheet metal" will occur. Industrial standards for the automotive body application, such as the construction of the body-in-white, dictate that the weld nugget should always fulfill the following relation.

Hence, the relevant failure mode for automotive body applications will be "cracking in the sheet metal". This failure mode is shown in the figure above. Due to this automotive guideline, the scope of application for both the NSSA and DSSA method is limited to this failure mode. [1].

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Spot weld fatigue life analysis bibliography

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