PNNL

Abstract

This paper summarizes work to date on resistance spot welding (RSW) of aluminum alloy to mild steel from process development to performance evaluation. A cold-rolled strip material is introduced as a transition material to aid the resistance welding process. The optimal welding parameters and electrode selections were established using a combination of experimental and analytical approaches. The mechanical behaviors of welded samples was evaluated using static and dynamic strength tests and cyclic fatigue tests. A statistical analysis was also performed to analyze the effect of different failure modes on the sample’s peak load and energy absorption.