Micromechanical evaluation of DP1000-GI dual-phase high-strength steel resistance spot weld

In situ micro-cantilever bending tests were carried out on resistance spot welded DP1000-GI dual-phase high-strength steel in order to derive the mechanical response of the welds. Notched micro-cantilevers were milled using focused ion beam milling at the base metal, inter-critical, fine-grained and coarse-grained heat affected zones, and fusion zone. It was shown that due to large plastic yielding, linear-elastic fracture mechanics are inapplicable. To evaluate the fracture toughness of different weld zones, cyclic loading was applied to track the crack size and the conditional fracture toughness of weld zones was measured using crack tip opening displacement and J-integral methods. It was found that micro-cantilever bending method provides insight to the fracture toughness and local mechanical response of different weld zones. The results obtained can be used to make an accurate correlation between resistance spot welding process, microstructure and mechanical response of DP1000-GI dual-phase high-strength steel welds.