Effect of electrode morphology on steel/aluminum alloy joint

Microstructure characteristics of dissimilar-metal resistance spot welded joints of SUS301 L austenitic stainless steel and 6063-T6 aluminum alloy, and effects of electrode morphology were studied. Results indicated that welded joints of dissimilar materials between austenitic stainless steel and aluminum alloy had characteristics of welding-brazing. The aluminum nugget consisted mainly of the cellular crystal, cellular dendrites and dendrites. The interface between austenitic stainless steel and aluminum alloy had a two-layered structures:a flat front surface θ-Fe_2Al_5 on the steel side and a serrated morphology θ-FeAl_3 on the aluminium alloy side, and it was the weakest zone of the joints. The electrode morphology had great effects on spot welded joints of stainless steel and aluminum alloy. The custom electrodes were a planar circular tip electrode with tip diameter of 10 mm on the stainless steel side and a spherical tip electrode with spherical radius of 35 mm on the aluminum alloy side. When the custom electrodes were used, the nugget diameter, tensile shear load and indentation ratio of spot welded joint were 7.22 mm, 3 606 N and 10.71%, respectively. The nugget diameter and joint tensile shear load increased by 34% and 102% respectively, and the indentation ratio decreased by 65% compared with the F-type electrodes(nugget diameter: 5.384 mm, tensile-shear load 1 783 N, indentation rate 30.94%). Therefore, it was more favorable to use the custom electrodes for improving the mechanical properties and appearance quality of resistance spot welded joints of stainless steel and aluminum alloy.     

Effects of nugget alloying on microstructures and properties of resistance spot welded joints of aluminum and steel

The resistance spot welding of 6063-716 aluminum alloy and l6 Mn steel was studied by nugget alloying.The results indicated that the Al-steel joint had characteristics of welding-brazing.The nugget zone consisted mainly of α-Al solid solution with dislocations and fine Mg_2Si particles.The interface zone had a double-layer structure:Fe_2Al_5 layer at steel side and Fe_4Al_(13) layer at Al nugget side.The nugget alloying has a significant effect on the joint properties by changing phase composition and refinement of grains.When alloy elements Cu,Zn,Ti and Ni were added,the tensile shear load of Al-steel joints reached 2 780 N,2 910 N,2 915 N and 2 929 N respectively,which increased by 24.1%,29.9%,30.1%and30.7%respectively compared with that(2 241 N) of joint without nugget alloying.Therefore,it is an effective way for improving mechanical properties of resistance spot welded Al-steel joints.