Recently, with automobile body weight reduction trend, aluminium alloy sheets are introduced to automotive moving parts such as hood, trunk, and tailgate. Researches about joining technologies on aluminium alloy sheet are necessary. However aluminium alloy has many troubles with spot weldability. In this study, we evaluate effects of electrode face radius and electrode force on weldability of resistance spot welding of aluminium alloy 6061. The two electrode face radius conditions showed the same acceptable welding current rage to produce acceptable spot welding quality. However, high electrode force showed larger welding current process window than low electrode force in resistance spot welding of aluminium alloy 6061

Aluminium alloy sheets are being utilized in automotive parts such as hood, trunk, and tailgate. However, the spot welding of aluminium alloy has many problems, such as electrode sticking and expulsion, and therefore research on the resistance spot welding of aluminium alloy sheets is necessary. In this study, we evaluated the effects of electrode face thickness on the resistance spot weldability of aluminium alloy 6061. The two electrode face thickness conditions were compared, and the electrode face thickness was determined to be an important process variable that affected the spot weldability of aluminium alloy 6061.

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