Abstract
Abstract Thermo-compensated resistance spot welding (RSW) with a Zn interlayer was designed to join AA5052-H12 (Al) aluminum alloy to AZ31B (Mg) magnesium alloy. A stainless steel tape placed between the upper electrode and the Al sheet acts as a heat barrier to prevent heat loss from the spot nugget on the Al side. During welding, more Al was melted to increase the percentage of Al in the liquid nugget. In the resultant Mg/Zn/Al joints produced by thermo-compensated RSW, the formation of Mg–Al brittle intermetallic compounds is restricted. The tensile–shear properties of the weld joint were improved significantly. The failure load of the Mg/Al joints was up to 2199 N, compared with the 833 N and 727 N that is produced by traditional Mg/Al RSW and Mg/Al RSW with Zn interlayer, respectively.
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