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Effect of Notch Geometry on Opening-Mode Pullout Failure of AHSS Resistance Spot Welds.

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Title: Effect of Notch Geometry on Opening-Mode Pullout Failure of AHSS Resistance Spot Welds.
Authors: Nadimi, Nima1 (AUTHOR), Pouranvari, Majid1 (AUTHOR) pouranvari@sharif.edu
Source: Metallurgical & Materials Transactions. Part A. Jul2026, Vol. 57 Issue 7, p3209-3222. 14p.
Subjects: Notch effect, Spot welding, Tension loads, High strength steel, Ductile fractures
Abstract: The failure behavior of resistance spot welds in advanced high-strength steels (AHSS) is traditionally attributed to nugget size and hardness characteristics; however, the influence of weld notch geometry has received limited attention. In this study, the effect of notch morphology on mode-I pullout failure was investigated in 1200 MPa martensitic AHSS under cross-tension loading. Two distinct notch shapes-sharp V-shaped and tongue-shaped-were produced through low-heat (LH) and high-heat (HH) welding schedules, respectively. Interrupted cross-tension tests revealed that notch geometry fundamentally controls the failure mechanism by dictating stress concentration, local constraint, and the effectiveness of the solid-state corona bond. LH welds, which develop a sharp notch and a weak corona bond, exhibit brittle cleavage initiated at the fusion boundary/upper-critical HAZ. Conversely, HH welds form a tongue-shaped notch with a continuous and strong corona bond, allowing strain localization in the softened subcritical HAZ (SCHAZ) and leading to ductile micro-void coalescence. These findings demonstrate that pullout failure is governed by the combined effect of notch geometry, corona bond integrity, and SCHAZ softening. The results highlight weld notch morphology as a critical geometric parameter that must be incorporated into predictive models and finite-element simulations for crashworthiness assessments of AHSS structures. [ABSTRACT FROM AUTHOR]
Copyright of Metallurgical & Materials Transactions. Part A is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 194517229
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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IllustrationInfo
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  Data: Effect of Notch Geometry on Opening-Mode Pullout Failure of AHSS Resistance Spot Welds.
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  Data: <searchLink fieldCode="AR" term="%22Nadimi%2C+Nima%22">Nadimi, Nima</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Pouranvari%2C+Majid%22">Pouranvari, Majid</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> pouranvari@sharif.edu</i>
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  Data: <searchLink fieldCode="JN" term="%22Metallurgical+%26+Materials+Transactions%2E+Part+A%22">Metallurgical & Materials Transactions. Part A</searchLink>. Jul2026, Vol. 57 Issue 7, p3209-3222. 14p.
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  Data: <searchLink fieldCode="DE" term="%22Notch+effect%22">Notch effect</searchLink><br /><searchLink fieldCode="DE" term="%22Spot+welding%22">Spot welding</searchLink><br /><searchLink fieldCode="DE" term="%22Tension+loads%22">Tension loads</searchLink><br /><searchLink fieldCode="DE" term="%22High+strength+steel%22">High strength steel</searchLink><br /><searchLink fieldCode="DE" term="%22Ductile+fractures%22">Ductile fractures</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: The failure behavior of resistance spot welds in advanced high-strength steels (AHSS) is traditionally attributed to nugget size and hardness characteristics; however, the influence of weld notch geometry has received limited attention. In this study, the effect of notch morphology on mode-I pullout failure was investigated in 1200 MPa martensitic AHSS under cross-tension loading. Two distinct notch shapes-sharp V-shaped and tongue-shaped-were produced through low-heat (LH) and high-heat (HH) welding schedules, respectively. Interrupted cross-tension tests revealed that notch geometry fundamentally controls the failure mechanism by dictating stress concentration, local constraint, and the effectiveness of the solid-state corona bond. LH welds, which develop a sharp notch and a weak corona bond, exhibit brittle cleavage initiated at the fusion boundary/upper-critical HAZ. Conversely, HH welds form a tongue-shaped notch with a continuous and strong corona bond, allowing strain localization in the softened subcritical HAZ (SCHAZ) and leading to ductile micro-void coalescence. These findings demonstrate that pullout failure is governed by the combined effect of notch geometry, corona bond integrity, and SCHAZ softening. The results highlight weld notch morphology as a critical geometric parameter that must be incorporated into predictive models and finite-element simulations for crashworthiness assessments of AHSS structures. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Metallurgical & Materials Transactions. Part A is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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      – Type: doi
        Value: 10.1007/s11661-026-08228-6
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 14
        StartPage: 3209
    Subjects:
      – SubjectFull: Notch effect
        Type: general
      – SubjectFull: Spot welding
        Type: general
      – SubjectFull: Tension loads
        Type: general
      – SubjectFull: High strength steel
        Type: general
      – SubjectFull: Ductile fractures
        Type: general
    Titles:
      – TitleFull: Effect of Notch Geometry on Opening-Mode Pullout Failure of AHSS Resistance Spot Welds.
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            NameFull: Nadimi, Nima
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            – D: 01
              M: 07
              Text: Jul2026
              Type: published
              Y: 2026
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              Value: 57
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            – TitleFull: Metallurgical & Materials Transactions. Part A
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