A Comparative Study on Complete and Partial Slot Filling in Automotive Chassis Welding for Fatigue Life Enhancement

A Comparative Study on Complete and Partial Slot Filling in Automotive Chassis Welding for Fatigue Life Enhancement | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article A Comparative Study on Complete and Partial Slot Filling in Automotive Chassis Welding for Fatigue Life Enhancement Sazzad Hossain Emon, Savyasachi Nellikode, Jeong Hoon Lee, Myung Hyun Kim, and 4 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5296457/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract The structural components of an automotive chassis, including critical elements like the frame and cross-members, must possess high strength to distribute and support the vehicle's load during operation effectively. In chassis manufacturing, slot welding has proven to be an effective method for improving support and durability under cyclical loading conditions. However, the absence of standardized guidelines for slot-filling during chassis welding poses a significant challenge, particularly concerning the fatigue life of components in the automotive industry. In this study, three different slot geometries were employed and welded by adjusting robotic programming to achieve complete filling (CF) or partial filling (PF) of the slots to improve fatigue life. A hot rolled 590 MPa steel sheet used for automotive applications with a cold metal transfer (CMT) technique was adopted to weld the samples. Digital image correlation (DIC) was conducted to identify stress concentration and the crack propagation path during the tensile loading of the sample. The fatigue crack initiation showed a location similar to the highest stress concentration area, as revealed by DIC. Additionally, an infrared camera was utilized during welding to monitor temperature variations, providing insights into the thermal aspects of each welding condition. The study revealed that higher effective weld width (W eff ) in the PF sample enhanced the tensile fatigue life by reducing stress concentration. However, the cross-tensile fatigue properties of the CF sample exhibited a longer fatigue life due to a larger weld size and associated weld width. Slot welding DIC Fatigue 590 MPa steel Automotive chassis Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 07 Nov, 2024 Reviewers invited by journal 06 Nov, 2024 Editor invited by journal 28 Oct, 2024 Editor assigned by journal 21 Oct, 2024 First submitted to journal 21 Oct, 2024 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5296457","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":374706797,"identity":"de84c3d5-6433-4cec-a4a8-48a91034d593","order_by":0,"name":"Sazzad Hossain 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Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Slot welding, DIC, Fatigue, 590 MPa steel, Automotive chassis","lastPublishedDoi":"10.21203/rs.3.rs-5296457/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-5296457/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe structural components of an automotive chassis, including critical elements like the frame and cross-members, must possess high strength to distribute and support the vehicle's load during operation effectively. In chassis manufacturing, slot welding has proven to be an effective method for improving support and durability under cyclical loading conditions. However, the absence of standardized guidelines for slot-filling during chassis welding poses a significant challenge, particularly concerning the fatigue life of components in the automotive industry. In this study, three different slot geometries were employed and welded by adjusting robotic programming to achieve complete filling (CF) or partial filling (PF) of the slots to improve fatigue life. A hot rolled 590 MPa steel sheet used for automotive applications with a cold metal transfer (CMT) technique was adopted to weld the samples. Digital image correlation (DIC) was conducted to identify stress concentration and the crack propagation path during the tensile loading of the sample. The fatigue crack initiation showed a location similar to the highest stress concentration area, as revealed by DIC. Additionally, an infrared camera was utilized during welding to monitor temperature variations, providing insights into the thermal aspects of each welding condition. The study revealed that higher effective weld width (W\u003csub\u003eeff\u003c/sub\u003e) in the PF sample enhanced the tensile fatigue life by reducing stress concentration. However, the cross-tensile fatigue properties of the CF sample exhibited a longer fatigue life due to a larger weld size and associated weld width.\u003c/p\u003e","manuscriptTitle":"A Comparative Study on Complete and Partial Slot Filling in Automotive Chassis Welding for Fatigue Life Enhancement","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-11-19 17:59:00","doi":"10.21203/rs.3.rs-5296457/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2024-11-07T09:39:37+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2024-11-06T07:46:35+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"Welding in the World","date":"2024-10-28T09:39:14+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2024-10-22T03:08:11+00:00","index":"","fulltext":""},{"type":"submitted","content":"Welding in the World","date":"2024-10-21T21:23:03+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"6ea6569b-194a-490a-914e-1a2c28400319","owner":[],"postedDate":"November 19th, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2025-01-06T09:09:36+00:00","versionOfRecord":[],"versionCreatedAt":"2024-11-19 17:59:00","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-5296457","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-5296457","identity":"rs-5296457","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}