Electrode pitting in resistance spot welding of aluminum alloy 5182 |
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| Authors: | I Lum E Biro Y Zhou S Fukumoto D R Boomer |
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| Affiliation: | (1) the Department of Mechanical Engineering, University of Waterloo, N2L 3G1 Waterloo, ON, Canada;(2) the Department of Materials Science and Engineering, Faculty of Engineering, Himeji Institute of Technology, Himeji, 671-2201 Hyogo, Japan;(3) Banbury Laboratory, Alcan International Limited, OX16 7SP Oxfordshire, United Kingdom |
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| Abstract: | Electrode pitting was investigated in resistance spot welding of 1.5-mm-thick sheet aluminum alloy 5182 using a medium-frequency
direct-current welder and electrodes with a tip face curvature radius of 50 mm and tip face diameter of 10 mm. Detailed investigation
of the metallurgical interactions between the copper electrode and aluminum alloy sheet was carried out using scanning electron
microscopy/energy-dispersive X-ray spectroscopy (SEM/EDX) and X-ray diffraction (XRD). The results indicated that electrode
degradation, which eventually leads to weld failure, proceeded in four basic steps: aluminum pickup, electrode alloying with
aluminum, electrode tip face pitting, and cavitation. Since pitting and cavitation result from Al pickup and alloying, periodic
electrode cleaning could extend electrode tip life by limiting the buildup of Al on the tip face. This work is part of the
effort to improve electrode tip life in resistance spot welding of aluminum alloys for automotive applications. |
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