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<p>Designers of welded structures usually have access to theoretical studies on structural impact, but few empirical results are publicly available. This study aims to better understand the effects of structural impact on welded structures, particularly when using filler metals with significantly different ductility, relevant to safety-critical automotive components such as heavy vehicle chassis, where impact resistance is crucial. Unlike previous studies focused on small-scale samples and standardized tests, such as Charpy, this research evaluates large-scale welded structures under conditions similar to real-world impact. Single-pass fillet welds were made on High-Strength Low-Alloy steel using Gas Metal Arc Welding with nickel-based and steel filler metals. Large-scale specimens were subjected to structural impact to determine the fracture threshold of these <i>as-welded</i> joints. The results show that welds with nickel-based filler metal absorbed 22.7% and 46.8% more energy and required 23.1% and 38.1% more impact energy for complete fracture than those with steel filler metal under longitudinal and transverse loading, respectively. After impact, an increase in hardness was observed in the weld metals and heat-affected zones. Additional tests showed that joints with nickel filler metal had lower load resistance in quasi-static shear tests, with reductions of 13% in the longitudinal and 8% in the transverse direction. In low-temperature impact tests (25 to − 50&#xa0;°C), L-shaped weldments with steel filler metal exhibited both ductile and brittle fracture characteristics. These findings provide valuable insights for industries requiring enhanced structural integrity under dynamic loading, demonstrating that the nickel electrode is a viable option for High-Strength Low-Alloy steel welding.</p>

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Structural Impact on High-Strength Low-Alloy Steel Structures Welded by Gas Metal Arc Welding with Nickel and Steel Filler Metals

  • 期刊论文

  • 发表日期：

    2025年5月9日

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  • Thiago da Silva Machado,
  • Ivan Guerra Machado

摘要

Designers of welded structures usually have access to theoretical studies on structural impact, but few empirical results are publicly available. This study aims to better understand the effects of structural impact on welded structures, particularly when using filler metals with significantly different ductility, relevant to safety-critical automotive components such as heavy vehicle chassis, where impact resistance is crucial. Unlike previous studies focused on small-scale samples and standardized tests, such as Charpy, this research evaluates large-scale welded structures under conditions similar to real-world impact. Single-pass fillet welds were made on High-Strength Low-Alloy steel using Gas Metal Arc Welding with nickel-based and steel filler metals. Large-scale specimens were subjected to structural impact to determine the fracture threshold of these as-welded joints. The results show that welds with nickel-based filler metal absorbed 22.7% and 46.8% more energy and required 23.1% and 38.1% more impact energy for complete fracture than those with steel filler metal under longitudinal and transverse loading, respectively. After impact, an increase in hardness was observed in the weld metals and heat-affected zones. Additional tests showed that joints with nickel filler metal had lower load resistance in quasi-static shear tests, with reductions of 13% in the longitudinal and 8% in the transverse direction. In low-temperature impact tests (25 to − 50 °C), L-shaped weldments with steel filler metal exhibited both ductile and brittle fracture characteristics. These findings provide valuable insights for industries requiring enhanced structural integrity under dynamic loading, demonstrating that the nickel electrode is a viable option for High-Strength Low-Alloy steel welding.