Abstract
Aluminum is a key lightweight material for reducing vehicle weight and improving fuel efficiency and is used in wrought, extruded, and cast forms. There is little research on resistance spot welding (RSW) of wrought-to-cast dissimilar aluminum alloys. For this paper, two types of electrodes were developed, and 2.3-mm 5182-O wrought and 4-mm AlSi10MnMg die cast sheets were welded by RSW with different electrode combinations. The results demonstrate that electrode geometry significantly influences the weld nugget morphology, weld performance, and failure mode. The proprietary Newton ring electrode produces the largest weld nugget size and consistent weld performance. Through the optimized electrode combination, severe weld nugget migration problems can be addressed for RSW of dissimilar aluminum alloys. Furthermore, the fracture crack under the tensile shear load always starts from the AlSi10MnMg side but not on the 5182-O side due to work hardening and concentration of stress regardless of whether the welds failed in the interfacial failure or pullout failure modes.
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