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<p>Using traditional resistance spot welding with a novel bulged double-helix electrode, 5182 aluminum alloy and DP780 galvanized steel were welded under two different current parameters. After baking, both samples exhibited a similar average peak load of 3.30&#xa0;kN, while defect locations showed significant differences. In the low-current sample, defects remained near the nugget center (11.64&#xa0;μm), whereas in the high-current sample, defects shifted farther away (1490.3&#xa0;μm). Crack initiation in both cases started along interfacial compounds at the weld edge. In the low-current sample, the crack propagated along interfacial defects on the aluminum side until complete fracture. In contrast, the high-current sample exhibited crack deflection into the aluminum, leading to a pullout fracture. The findings highlight the influence of post-welding baking on the durability and performance of welded joints. This study provides valuable insights for optimizing aluminum-steel resistance spot welding in industrial applications, particularly for reliability after baking.</p>

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Effect of baking on mechanical properties of 5182 aluminum/DP 780 steel spot welding joints

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年11月10日

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  • Sai Zhang,
  • Xuan Shi,
  • Tao Li,
  • Xian-Ming Meng,
  • Cong-Qian Cheng,
  • Xiao-Zhong Wu,
  • Tie-Shan Cao,
  • Jie Zhao

摘要

Using traditional resistance spot welding with a novel bulged double-helix electrode, 5182 aluminum alloy and DP780 galvanized steel were welded under two different current parameters. After baking, both samples exhibited a similar average peak load of 3.30 kN, while defect locations showed significant differences. In the low-current sample, defects remained near the nugget center (11.64 μm), whereas in the high-current sample, defects shifted farther away (1490.3 μm). Crack initiation in both cases started along interfacial compounds at the weld edge. In the low-current sample, the crack propagated along interfacial defects on the aluminum side until complete fracture. In contrast, the high-current sample exhibited crack deflection into the aluminum, leading to a pullout fracture. The findings highlight the influence of post-welding baking on the durability and performance of welded joints. This study provides valuable insights for optimizing aluminum-steel resistance spot welding in industrial applications, particularly for reliability after baking.