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Disjoining of spot welds in steel sheets because of fatigue failure is one of the main reasons for noise in used cars. Fatigue life of spot welding connections of ST12 steel sheets, used in car industry, with 6mm nugget diameter and subjected to uniaxial dynamic shear load is studied and determined in this research. Sheet thickness and other spot welding parameters including weld pitch are considered and compared according to C-G006 standard utilizing the test sample selected according to DIN50165 standard. ABAQUS and FE-SAFE soft wares are used for static and fatigue life analysis respectively. To generate Stress-Number of life cycle (S-N) diagram, the equivalent fully reversed load is determined using Goodman and Gerber theories since the applied load is unidirectional. The resultant finite element results were verified experimentally by a fatigue test machine designed and manufactured during this study by the authors. The finite element results showed a good agreement with Gerber criterion and it was concluded that with increase in sheet thickness, both static strength and fatigue life would be increased. The results also depicts that the weld pitch has no effect on fatigue life. Stress – life graph for 6mm nugget diameter spot weld on ST12 sheet is the most important outputs of this research that can be used in automobile industry.

Keywords: Fatigue Life, Resistance spot welding, Finite Element, Fatigue test machine

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