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This paper investigated various aspects of replacing existing micro-resistance spot welding (micro-RSW) with micro-laser spot welding for joining Inconel 718 thin foils to thick 410 steel stack-up to allow faster, non-contact joining together with flexibility in spot positioning and removal of tip dressing required for RSW electrodes. The joint quality was evaluated based on the mechanical strength, microstructural characteristics and joint strength at elevated temperature as these joints are often used for high-temperature applications. Experimental investigations were performed using micro-RSW and micro-laser spot welding to obtain the 90° peel and lap shear specimens, each comprising four spots. The obtained strength from laser joints was significantly higher than that of micro-RSW joints due to larger weld nugget formation and interface width. The process map for obtaining good quality welds was also identified, and about a 17% reduction in joint strength was obtained when welded specimens were subjected to elevated temperature (i.e., 500 °C) in comparison with room temperature. This reduction was compensated for using the flexibility of laser welding to add two extra spots. The overall performance of the micro-laser spot welds was found to be better than the micro-RSW considering joint strength, flexibility in placing the spots and time to produce the welds.

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AA6010 in the F temper was investigated using a Gleeble 3800 test rig across a range of temperatures (350–550 °C) and strain rates (1 × 10−1 s−1 1 × 101 s−1) to identify optimal forming conditions. Post-forming electron back-scattered diffraction analysis was conducted to identify the mechanisms responsible for the material formability. Optimal forming conditions were observed to be 500 °C and a strain rate of 1 × 10−1 s−1, with clear evidence of dynamic recrystallisation observed, this being the dominant mechanism responsible for the increased formability. Peak yield strength of 335 MPa was achieved using a rapid aging treatment of 205 °C for one hour.