Influence of working condition fluctuation on resistance spot welding of aluminum alloy and steel
CHEN Jiaxuan
HU Shanqing
LI Zhuoran
HU Qingbang
MA Yunwu
XIA Yujun
LI Yongbing
Abstract：Under the background of automotive lightweighting,the use of resistance spot welding to achieve effective connection of aluminum to steel structures is an unremitting pursuit.However,in actual welding production,fluctuation of working conditions occur frequently,seriously affecting the quality of weld points.Firstly,the resistance spot welding process was adopted to connect aluminum alloy and low-carbon steel plates.The influences of different inclination angles,plate gaps,and fluctuations in cooling water flow conditions on the resistance spot welding of aluminum-steel were investigated.Then,the quality of the weld points was evaluated by comparing the diameter and thickness of the nugget,the thickness of the intermetallic compound,the coach peel performance,as well as the fracture mode.The research results show that an increase in the inclination angle and the gap between the plates within a certain range,as well as a decrease in the cooling water flow within a certain range,will both reduce the quality of the weld points.Therefore,they should be avoided as much as possible in actual production.The results of this study provide a theoretical basis and practical guidance for optimizing the resistance spot welding process of aluminum to steel.
Keywords：Resistance spot weldingWorking condition fluctuationIntermetallic compoundCoach peel performanceFracture mode
Publication Date：2025-09-15
Online Publishing Date：2026-09-12(First online date of this platform, not the publication date of the document)
Pages：10( 80-89 )