EFFECT OF RESISTANCE SPOT WELDING PARAMETERS  ON THE QUALITY OF THE WELD JOINT  BETWEEN ALUMINUM ALLOY AND LOW CARBON STEEL

Van Nhat Nguyen; Minh Tan Nguyen

Van Nhat Nguyen Faculty of Mechanical Engineering, Hung Yen University of Technology and Education
Minh Tan Nguyen Faculty of Mechanical Engineering, Hung Yen University of Technology and Education

Abstract

In recent years, welding joints between aluminum alloy and low carbon steel has attracted the great attention of researchers. This paper presents a study on the influence of welding current (I_h) and electrode force (F) in the electric resistance welding method on the quality of the welding joint between AA6061-T6 aluminum alloy and SS400 low carbon steel. The microstructure and mechanical properties of the welded joint are the selected quality characteristics for investigation. Optical microscopy, scanning electron microscopy, and EDX linescan techniques were used to examine the cross-sectional microstructure of the weld. Research results show that the welding current and electrode force have a great influence on the quality of the welding joint. The weld spot dimensions and the shear strength of the joint increase as the electrode force and welding current are increased. The best quality welding joint, the greatest shear strength, no defects when the I_h = 3000 A and the F = 25 Psi. The weld does not melt when the I_h is less than 2000 A and the F is less than 15 Psi. An intermetallic layer was found at the interface between steel and the weld metal, the intermetallic layer thickness increased as I_h, F increased. The cross-sectional estimate of the welded joint also revealed the existence of micro-cracks, incomplete fusion and metal loss.

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