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Resistance microwelding of fine crossed nickel wires is of increasing industrial importance for electrical connections in downsized electronic and medical devices, but the understanding of the process is very limited. A study has, therefore, been performed to clarify the basic joining mechanisms, in which the effects of main process parameters (welding current and force and weld time) were investigated by detailed mechanical testing and metallurgical examinations. A bonding mechanism with main process stages (wire cold collapse, surface melting, molten-phase squeeze-out and, solid-state bonding) was proposed. A new technique has also been developed to optimize the process by initiating the welding current well before the electrode force has reached its full nominal value.

Microstructure and mechanical properties of the dissimilar aluminium-magnesium resistance spot welds made with gold coated and bare nickel interlayers are investigated. Welds were made with different welding currents in a range from 16 to 24 kA with a fixed welding time of five cycles. No joints were achieved with a bare nickel interlayer; after welding, specimens were separated without applying any force. Addition of gold coating on nickel surface greatly contributed to the metallurgical bonding at the interfaces and welds easily met requirements of AWS D17?2 standard. Average lap shear strength reached 90% of similar AZ-31B spot weld strength. Fusion nugget size, interfacial microstructure and fracture surface morphology of the welds were analysed.