Abstract
Welding parameters obviously determine the joint quality during the resistance spot welding process. This study aimed to investigate the effect of welding current and electrode force on the heat input and the physical and mechanical properties of a SS316L and Ti6Al4V joint with an aluminum interlayer. The weld current values used in this study were 11, 12, and 13 kA, while the electrode force values were 3, 4, and 5 kN. Welding time and holding time remained constant at 30 cycles. The study revealed that, as the welding current and electrode force increased, the generated heat input increased significantly. The highest tensile-shear load was recorded at 8.71 kN using 11 kA of weld current and 3 kN of electrode force. The physical properties examined the formation of a brittle fracture and several weld defects on the high current welded joint. The increase in weld current also increased the weld diameter. The microstructure analysis revealed no phase transformation on the SS316L interface; instead, the significant grain growth occurred. The phase transformation has occurred on the Ti6Al4V interface. The intermetallic compound layer was also investigated in detail using the EDX (Energy Dispersive X-Ray) and XRD (X-Ray Diffraction) analyses. It was also found that both stainless steel and titanium alloy have their own fusion zone, which is indicated by the highest microhardness value.
Highlights
Resistance spot welding has been intensively used in automotive and aerospace industries to perform rapid and efficient manufacturing processes
Resistance spot welding is a thermal joining process involving heat as a major parameter to create a joint between two pieces of metal
According to Joule’s law, the amount of generated heat on resistance spot welding depends on several factors, such as the weld current which flows through the amperage, the welding time which conducts the heating process at a certain time, and the resistance of the materials during the welding process
Summary
Resistance spot welding has been intensively used in automotive and aerospace industries to perform rapid and efficient manufacturing processes. Considering the additional weight caused by inefficient joining techniques, a recent study by Costanza et al investigated explosion welding, that could be an option to join dissimilar materials without additional weight [4]. This method is effective to reduce the additional weight on the joint, the joining process is less effective for the automotive and aerospace industry due to the complex equipment needed and difficulties in defining the optimum welding parameters. In order to gain a good quality and efficient product, the combinations between two dissimilar materials are implemented using the resistance spot welding method
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