Abstract
Resistance element welding (REW) is an effective method for joining dissimilar materials by applying an auxiliary element in resistance spot welding (RSW). In this paper, 6061-T6 aluminum alloy/carbon fiber reinforced thermoplastic (CFRTP) joints were produced via REW. The macrostructure, microstructure, microhardness distribution and tensile shear performance of the joints obtained via REW were investigated. The effects of welding parameters on the nugget formation and joint performance during REW were investigated. Studied the joining mechanism by microscopic observation and mapping. Conducted fractography by macroscopic 3D observation and scanning electron microscope (SEM) observation. It is found that in a certain range, the interface nugget diameter increases with the increase of heat input, resulting in the increase of tensile peak load. The maximum peak tensile shear loads of the REWed joints were 3788.06 N. The failure mode of the REW joints changed from interface mode to partial button fracture with an increase in welding current under the same welding time and electrode pressure.
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