Influence of sample preparation and geometrical deviation on the destructive testing outcomes of RSW joints in AHSS

Abstract

This study emphasizes the critical importance of sample preparation in resistance spot welding (RSW) for ensuring the integrity and reliability of the welding process, particularly when dealing with high-strength materials (dual phase DP600 and martensitic steel MS1400). By conducting a series of experiments that introduce various geometrical inaccuracies, such as misalignment and dimensional errors, the study quantifies their impact on tensile strength, displacement, and failure modes during tensile-shear and cross-tension tests. Key aspects such as spot welder calibration, surface conditions, dimensional accuracy, and alignment procedures are thoroughly examined. The investigation reveals that geometrical deviations in specimen preparation can significantly affect the mechanical properties assessment of welded joints.