Effects of process parameters on the mechanical properties of dissimilar thin Al welds

Abstract

Abstract One of the major challenges in the resistance spot welding of thin materials is deformation during the welding process. In this study, the resistance spot welding of two different thin aluminum materials (AA1050−O with a thickness of 0.5 mm and AA5754−H111 with a thickness of 1 mm) was investigated. The effects of welding current and welding time parameters on the mechanical properties (including tensile shear strength and hardness), the nugget formation and the fracture type were analyzed and evaluated. Microstructure evolutions of the deformation process were performed via SEM. As a result, it was seen that increasing welding current leads to an increase in strength and hardness of the joints due to button pull out failure. The best mechanical properties within the parameters were observed when the welding current was at 19 kA, with 5 cycles.