Resistance spot welding of dissimilar alloys 1008 low carbon steel5052 aluminum alloy

Abstract

The resistance spot welding is adopted to joint dissimilar alloys such as aluminum alloy 5052, and low carbon steel alloy 1008. In this work, the electrodes force 2100-2700 N, the welding current 7. 5-10.5

Resistance Spot Welding of Dissimilar Alloys 1008 Low Carbon Steel- 1100 Aluminum Alloy

“…For the Al side, the fine hardness values of FZ and HAZ are less than those of BM, and HAZ also exhibits a little softening area. The same results were obtained by [22].…”

“…the relationship between the electrode force and nugget diameter, the diameter increased with increased of electrode force at welding current below 8 KA while after 8 KA the diameter reduced to low value. Insufficient electrode force would result in high contact resistance, excessive heat generation, expulsion, and poor joint quality the same results have been reached by‖ [21,22,23].…”

“…It shows that the increasing of weld current from 7.5-10.5 KA, the thickness of intermetallic compound layer (IMC) decreases from 8-4 μm. Hence, the strength of the weld joint increases from 1800 to 2860 N. The discontinuous intermetallic compound layer (IMC) turns into a continuous layer when approaching the center of the weld nugget (Mohammad Jameel Zedan et al 2018) [17]. The using of zinc layer in the welding process will improve the welding.…”

Microstructural and mechanical characterization of steel-DP780/Al-5052 joints formed using resistance element welding with concealed rivet cover

“…1 Resistance spot welding (RSW), a fusion welding process, is widely used in the production of automobile body welding assembly and auto parts because it is fast, efficient, inexpensive, and easily mechanized and automated, along with yielding good welding surface quality. [2][3][4][5] Although RSW plays a vital role in the quality of automotive manufacturing, [6][7][8][9] its application in joining aluminum alloys and steel is challenging and presents two difficulties [10][11][12][13][14][15] : (1) The widely varying thermophysical properties of aluminum alloy and steel, such as melting point, thermal conductivity, and coefficient of linear expansion, are a source of significant stress on the joints after welding, increasing their susceptibility to cracking. (2) Under the influence of heat due to electric resistance, the aluminum alloy and steel form a series of intermetallic compounds (IMCs) at the spot-welding interface, rendering the latter extremely brittle and weak.…”