Drawn arc aluminum stud welding for automotive applications

Federal regulations have been enacted to significantly reduce atmospheric pollution caused by motor vehicles. This forced the automotive manufacturers to improve fuel efficiency of cars and light trucks by using lightweight materials such as aluminum. The focus of the current study is to develop welding procedures using the drawn arc process for 5754-0 and 6061-T6 aluminum alloys. The mechanical and macrostructural characteristics of the welded joints were evaluated using tensile tests, torque tests, and optical microscopy. Preliminary study indicates that these alloys can be welded with a minimal amount of porosity and good mechanical properties.