Abstract
This chapter discusses the relationship between fusion zone size and weld performance for aluminum resistance spot welds. Weld performance in terms of failure modes, static strength and energy absorption is examined using a combined experimental, statistical and analytical approach. The main failure modes for aluminum spot welds are nugget pullout and interfacial fracture. It is found that fusion zone size, sheet thickness and the level and location of weld porosity/defects are the main factors influencing the cross-tension failure mode of an aluminum spot weld. Two additional spot weld populations with different fusion zone sizes are used to validate the analytical failure mode model.
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