Combined numerical and experimental estimation of the fracture toughness and failure analysis of single lap shear test for dissimilar welds

The single lap shear test is widely used to measure the strength of dissimilar welds even though such a brings limited understanding intrinsic weld toughness. present study proposes numerical finite element (FE) analysis and experimental characterization joints presenting various microstructures (thickness intermetallic layer (IML) hardness profile). For this purpose, Friction Melt Bonding (FMB) Stir Welding (FSW) were join aluminum AA6061 Dual Phase steel (DP980). FE simulations allowed calculating evolution J-integral near notch tip. It shows that crack initiation depends significantly on plastic properties welded metallic alloys around tip width zone, which both are different for FSW FMB processes. Nevertheless, similar fracture toughness JC approximately 1 kJ.m?2 estimated from FSW. This three orders magnitude higher than layer, revealing dissipation in Al plates has major effect