Abstract
In part I of this paper, a novel process, i.e., metallic bump assisted resistance spot welding (MBaRSW) process was proposed to improve Al/steel resistance spot weld properties, in which the bump could be printed on either aluminum or steel sheet using a modified cold metal transfer (CMT) pin process. Part II focused on formation mechanism and mechanical properties of the MBaRSW welds through comparing with traditional resistance spot welding (RSW) process. Results showed that the MBaRSW welds were defect-free and had larger nugget size, smaller thinning and thinner intermetallic compound (IMC) layer within a wider acceptable welding current range, resulting in 27% and 30% higher lap-shear strength for MBaRSW/Al and MBaRSW/St welds, respectively. Moreover, both the nugget diameter and lap-shear strength of the novel welds met requirements that the minimum acceptance nugget size and the weld strength higher than Al-Al RSW weld. The MBaRSW joints fractured with a mixed mode, different from low-ductility interfacial failure mode of the traditional RSW ones. The novel process had an excellent energy-saving effect and no need of aluminum oxide film removal prior to welding, exhibiting great advantages over the traditional process.
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