Abstract
In order to get a defect free spot weld, both the metals are desired to have the same thermal and electrical conductivity. But when welding dissimilar metals or sheets of different thickness, the fusion zone of both the metals may not experience same heat input due to the difference in material properties. This leads to weld defects such as nugget offset, voids and intergranular cracks in the fusion zone. The existence of weld defects deteriorates the mechanical performance of welded joints. A thorough metallurgical analysis must be carried out to ensure that the weld nugget is free of defects. The resistance spot welding of various dissimilar metals in the recent research publications and its practical outcomes are analyzed.
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