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Fatigue failures of spot friction welds in lap-shear specimens of aluminum 6111-T4 sheets under cyclic loading conditions are investigated in this paper. The paths of fatigue cracks near the spot friction welds are first discussed. A fatigue crack growth model based on the Paris law for crack propagation and the global and local stress intensity factors for kinked cracks is then adopted to predict the fatigue lives of these spot friction welds. The global stress intensity factors and the local stress intensity factors based on the recent published works for resistance spot welds in lap-shear specimens are used to estimate the local stress intensity factors for kinked cracks with experimentally determined kink angles. The results indicate that the fatigue life predictions based on the Paris law and the local stress intensity factors as functions of the kink length agree well with the experimental results.

Sandwich specimens with DP590 steel face sheets and structural epoxy foam cores are investigated under three-point bending conditions. Experimental results indicate that the maximum loads correspond to extensive cracking in the foam cores. Finite element simulations of the bending tests are also performed to understand the failure mechanisms of the epoxy foams. In these simulations, the plastic behavior of the steel face sheets is modeled by the Mises yield criterion with consideration of plastic strain hardening. A pressure sensitive yield criterion is used to model the plastic behavior of the epoxy foam cores. The epoxy foams are idealized to follow an elastic perfectly plastic behavior. The simulation results indicate that the load-displacement responses of some sandwich specimens agree with the experimental results.