Abstract
The surface coating of steel significantly impacts intermetallic compounds (IMC) distribution and the performance of steel aluminum resistance spot welding (RSW) joints. In this paper, four sheets of steel with different surface coating were individually designed for welding with aluminum alloy. The results showed that the welded steel with coating performs better than that of Bare plate, while the welded steel with galvannealed (GA) coating has better performance than galvanized (GI) coating. The joints with GA coating failed in button pullout (PF) under tensile shear tests, while others failed in an interface (IF). The reason can be that the surface alloying zinc plating helps improve the combination reaction of Fe and Al, and the Zn will undergo a ternary combination reaction with Fe and Al to form a new compound containing Zn. The presence of the Zn layer can promote the interfacial reaction between steel and aluminum, and the welded joint performance reduces the impact of oxide film, even when the coating is thicker than 10 μm.
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