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<p>The Laser spot weld-bonding (LSWB) is increasingly adopted in SUS301L-MT stainless steel railcar bodies. However, the influence of adhesives on LSWB mechanical properties and weld quality remains unclear. In this study, LSW/LSWB single-lap joints were fabricated using three epoxy adhesives (DP-190, DP-420, and DP-460) with a 1000&#xa0;W continuous-wave fiber laser. Tensile tests and defect evaluations were conducted, and refined (solid) and simplified (MPC + beam) numerical models suitable for engineering assessments were constructed and validated. Results indicate that LSW joints exhibited a single-peak load-displacement response, whereas LSWB joints exhibited a double-peak response. Compared to that of LSW joints (0.943kN; 0.201&#xa0;mm), the overall strength (18.512 ~ 28.243kN) and ductility (0.687 ~ 0.982&#xa0;mm) of LSWB joints were higher, despite defect-induced reductions in weld spot strength (0.625 ~ 0.941kN). LSWB-DP-420 exhibited the highest strength (28.243kN) with mixed failure. Despite the highest nominal shear strength of the DP-460, LSWB-DP-460 joints exhibited the lowest strength (18.512kN) and interfacial failure due to insufficient mechanical interlocking. Welding-induced adhesive pyrolysis caused defects, including reduced weld pool areas (−8.9 ~ −49.3%) and increased weld crown height (+107.3 ~ 762.1%), with defect severity increasing in the order of DP-190, DP-420, and DP-460, consistent with the loss of weld spot strength. Both numerical models achieved an average relative error of less than 10%, with the simplified model offering an optimal balance between accuracy and computational efficiency for engineering applications. This study reveals the effects of dissimilar adhesives on LSWB, providing support for its application.</p>

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Experimental and numerical analysis of laser spot weld bonding single-lap joints of SUS301L stainless steel with dissimilar adhesives

  • 期刊论文

  • 发表日期：

    2026年1月16日

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  • Dailin Zhang,
  • Xiaofeng Li,
  • Ji Fang,
  • Yanyang Li,
  • Ningxin Xue

摘要

The Laser spot weld-bonding (LSWB) is increasingly adopted in SUS301L-MT stainless steel railcar bodies. However, the influence of adhesives on LSWB mechanical properties and weld quality remains unclear. In this study, LSW/LSWB single-lap joints were fabricated using three epoxy adhesives (DP-190, DP-420, and DP-460) with a 1000 W continuous-wave fiber laser. Tensile tests and defect evaluations were conducted, and refined (solid) and simplified (MPC + beam) numerical models suitable for engineering assessments were constructed and validated. Results indicate that LSW joints exhibited a single-peak load-displacement response, whereas LSWB joints exhibited a double-peak response. Compared to that of LSW joints (0.943kN; 0.201 mm), the overall strength (18.512 ~ 28.243kN) and ductility (0.687 ~ 0.982 mm) of LSWB joints were higher, despite defect-induced reductions in weld spot strength (0.625 ~ 0.941kN). LSWB-DP-420 exhibited the highest strength (28.243kN) with mixed failure. Despite the highest nominal shear strength of the DP-460, LSWB-DP-460 joints exhibited the lowest strength (18.512kN) and interfacial failure due to insufficient mechanical interlocking. Welding-induced adhesive pyrolysis caused defects, including reduced weld pool areas (−8.9 ~ −49.3%) and increased weld crown height (+107.3 ~ 762.1%), with defect severity increasing in the order of DP-190, DP-420, and DP-460, consistent with the loss of weld spot strength. Both numerical models achieved an average relative error of less than 10%, with the simplified model offering an optimal balance between accuracy and computational efficiency for engineering applications. This study reveals the effects of dissimilar adhesives on LSWB, providing support for its application.