Abstract
A reduced-current resistance spot welding technique, which uses the heat of formation from reactive inserts together with the Joule's heat, is presented. Employing elemental powder mixtures of titanium and aluminum as the reactive inserts, drastic decreases in the welding current were achieved in aluminum sheet joints ; for example welding current of 7 kA was sufficient to join aluminum sheets of 2 mm in thickness. Welded joints exhibited higher tensile shear strengths without any brushing treatments prior to resistance spot welding, due to evaporation of volatile impurities at high temperatures reached during reaction of the inserts. An aluminum alloy sheet, A5052-H34, with a thickness of 1 mm was successfully welded by the reactive insert method under the welding conditions usually used for steel panels in automobile assembly lines.
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