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Assessment of the fatigue life of aluminium spot-welded and weld-bonded joints

In modern machinery and automobile structures weight reduction and increased durability are the main issues in design. In these applications, lap welded and/or bonded joints are widely used; therefore, tools are needed to accurately predict their fatigue life. This paper is concerned with the fatigue strength of single lap joints formed with thin plates of 6082-T6 aluminium alloy using a high strength two-component epoxy adhesive (Araldite 420 A/B from Hunstman). Experimental S–N curves were obtained for resistance spot-welded and weld-bonded lap joints. The fatigue lives of weld-bonded joints were significantly higher than those of resistance spot-welding joints. In addition, fatigue lives were predicted with Morrow's modified Manson–Coffin (M/M–C) and the Smith–Watson–Topper (S–W–T) damage equations. Elastic–plastic numerical models were developed, replicating the experimental work, in order to obtain local stress and strain fields. An acceptable agreement was obtained between the numerical predictions and the experimental results. The M/M–C damage equation diverged from experimental results for relatively long fatigue lives, while the S–W–T equation gave good predictions for all fatigue lives.