Abstract
A novel spot joining technique (i.e., resistance spot clinching) that has the features of resistance spot welding and mechanical clinching is introduced. This technique was compared with typical resistance spot welding to show the effect of the surface oxide layer on the joining quality of aluminum alloy 5052 sheets. The oxide film increases the contact resistance at each interface and makes it unstable. In both resistance spot welding and resistance spot clinching, the critical current for expulsion is lowered by oxide on the workpiece surface. However, the surface oxide layer has less effect on the stability of joining quality in resistance spot clinching. That is because in resistance spot clinching process, the melting of the workpiece is mainly caused by the Joule heat of the contact resistance between processing tape and aluminum alloy 5052 sheets (which is less affected by the surface oxide layer). Thus, the fluctuation of the contact resistance in resistance spot clinching is lower than that of resistance spot welding.
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