By: Renu, Neeraj Bisht, Sonika Chauhan, and Nisha Rani
1Lecturer, Mechanical Engineering, Govt. Polytechnic, Bazpur.
2, 3Assistant Professor, Mechanical Engineering Department, Govind Ballabh Pant University of Agriculture and Technology, Pantnagar, India.
4Ph.D. Scholar, Mechanical Engineering Department, Govind Ballabh Pant University of Agriculture and Technology, Pantnagar, India.
An extensive analysis of resistance spot welding in dissimilar metals is presented in this review paper. Resistance spot welding (RSW) is a joining technique that is frequently used in various sectors and most importantly in automotive sectors because of its effectiveness and efficiency in creating strong welded joints. This paper provides basic understanding of the various aspects of work done on dissimilar metals. It also gives an understanding of the factors affecting the mechanical properties and micro-structure of the RSW joint. This paper also discusses the effects of filler materials on different dissimilar metal combinations and the effect of intermetallic compound layer on the RSW welded joint.
Citation:
Refrences:
1. Charde N, Yusof F, Rajkumar R. Material characterizations of mild steels, stainless steels and both steel mixed joints under resistance spot welding (2-mm sheets). Int J Adv Manuf Technol. 2014;75(1–4):373–384.
2. Kocabekir B, Kacar R, Gündüz S, Hayat F. An effect of heat input, weld atmosphere and weld cooling conditions on the resistance spot weldability of 316L austenitic stainless steel. J Mater Process Technol. 2008;195(1):327–335.
3. Liu L, Feng J, Zhou Y. Resistance spot welding of magnesium alloys. In: Liu L, editor. Welding and joining of magnesium alloys. Woodhead Publishing; 2010. p. 351–367.
4. Lee M, Jung S. Trends of Advanced Multi-Material Technology for Light Materials based on Aluminum. J. Weld. Join. 2016;34(5):19–25. doi:10.5781/JWJ.2016.34.5.19.
5. Kang M, Kim C. A review of joining processes for high strength 7xxx series aluminum alloys. J Weld Join. 2017;35(6):79-88. doi:10.5781/jwj.2017.35.6.12.
6. Musfirah AH, Jaharah AG. Magnesium and aluminum alloys in the automotive industry. J Appl Sci Res. 2012;8(9):4865–4875.
7. Miller WS, Zhuang L, Bottema J, Wittebrood AJ, De Smet P, Haszler A, et al. Recent development in aluminum alloys for the automotive industry. Mater Sci Eng A. 2000;280(1):37–49. doi:10.1016/S0921-5093(99)00653-X.
8. Qiu R, Iwamoto C, Satonaka S. Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate. J Mater Process Technol. 2009;209(8):4186–4193..
9. Alizadeh-Sh M, Marashi S, Pouranvari M. Resistance spot welding of AISI 430 ferritic stainless steel: phase transformations and mechanical properties. Mater Des. 2014;56:258–263.
10. Dancette S, Fabrègue D, Massardier V, Merlin J, Dupuy T, Bouzekri M. Experimental and modeling investigation of the failure resistance of advanced high strength steels spot welds. Eng Fract Mech. 2011;78(10):2259–2272.
11. Zhang H, Qiu X, Xing F, Bai J, Chen J. Failure analysis of dissimilar thickness resistance spot welded joints in dual-phase steels during tensile shear test. Mater Des. 2014;55:366–372.
12. Sun M, Niknejad ST, Zhang G, Lee MK, Wu L, Zhou Y. Microstructure and mechanical properties of resistance spot welded AZ31/AA5754 using a nickel interlayer. Mater Des. 2015;87:905–913.
13. Zhang W, Sun D, Han L, Li Y. Optimised design of electrode morphology for novel dissimilar resistance spot welding of aluminum alloy and galvanised high strength steel. Mater Des. 2015;85:461–470.
14. Lu Y, Mayton E, Song H, Kimchi M, Zhang W. Dissimilar metal joining of aluminum to steel by ultrasonic plus resistance spot welding—microstructure and mechanical properties. Mater Des. 2019;165:107585.
15. Arghavani MR, Movahedi M, Kokabi AH. Role of zinc layer in resistance spot welding of aluminum to steel. Mater Des. 2016;102:106–114.
16. Hendrawan MA, Purboputro PI, Prima A. Use of zinc powder on resistance spot welding on mild steel and aluminum. In: Journal of Physics: Conference Series. 2021 Apr;1858(1):012051. IOP Publishing.
17. Wan Z, Wang HP, Chen N, Wang M, Carlson BE. Characterization of intermetallic compound at the interfaces of Al-steel resistance spot welds. J Mater Process Technol. 2017;242:12–23.
18. Qiu R, Iwamoto C, Satonaka S. Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate. J Mater Process Technol. 2009;209(8):4186–4193.
19. Chen N, Wang HP, Carlson BE, Sigler DR, Wang M. Fracture mechanisms of Al/steel resistance spot welds in lap shear test. J Mater Process Technol. 2017;243:347–354.
20. Chen J, Yuan X, Hu Z, Li T, Wu K, Li C. Improvement of resistance spot welded joints for DP 600 steel and A5052 aluminum alloy with Zn slice interlayer. J Manuf Process. 2017;30:396–405.
21. Shi L, Kang J, Chen X, Haselhuhn AS, Sigler DR, Carlson BE. Determination of fracture modes in novel aluminum-steel dissimilar resistance spot welds. Procedia Struct Integr. 2019;17:355-362.
22. Al-Filfily AA, Al-Adili AS, Sar MH. Strength of resistance spot welding of aluminum alloy AA6061 to carbon steel using different filler materials. In: IOP Conference Series: Materials Science and Engineering. 2020 Jul;881(1):012067. IOP Publishing.
23. Hu S, Haselhuhn AS, Ma Y, Li Y, Carlson BE, Lin Z. Comparison of the resistance spot weldability of AA5754 and AA6022 aluminum to steels. Weld J. 2020;99(8):224S-238S.
24. Kang J, Shi L, Shalchi-Amirkhiz B, Sigler DR, Haselhuhn AS, Carlson BE. Microstructure and shear strength of novel aluminum to steel resistance spot welds. Weld J. 2020;99:67-s.
25. Kapil A, Mao Y, Vivek A, Cooper R, Hetrick E, Daehn G. A new approach for dissimilar aluminum-steel impact spot welding using vaporizing foil actuators. J Manuf Process. 2020;58:279-288.
26. Liu F, Hou Q, Hu H, Ma Y, Ning S, Wu Y. Study on microstructure and properties of resistance spot welding of Mg/Ti dissimilar materials. Sci Technol Weld Joining. 2020;25(7):581-588.
27. Shi L, Kang J, Gesing M, Chen X, Haselhuhn AS, Carlson BE. Effect of notch root angle on fatigue behavior of aluminum to steel resistance spot welds. Int J Fatigue. 2020;141:105866.
28. Mishra D, Rajanikanth K, Shunmugasundaram M, Kumar AP, Maneiah D. Dissimilar resistance spot welding of mild steel and stainless steel metal sheets for optimum weld nugget size. Mater Today Proc. 2021;46:919-924.
29. Chen J, Yuan X, Hu Z, Sun C, Zhang Y, Zhang Y. Microstructure and mechanical properties of resistance spot welded joints for A5052 aluminum alloy and DP 600 steel. Mater Charact. 2016;120:45-52.
30. Chen L, Zhang Y, Xue X, Wang B, Yang J, Zhang Z, Tyrer N, et al. Investigation on shearing strength of resistance spot welded joints of dissimilar steel plates with varying welding current and time. J Mater Res Technol. 2022;16:1021-1028.
31. Oliveira JP, Ponder K, Brizes E, Abke T, Edwards P, Ramirez AJ. Combining resistance spot welding and friction element welding for dissimilar joining of aluminum to high strength steels. J Mater Process Technol. 2019;273:116192.
32. Shi L, Xue J, Kang J, Haselhuhn AS, Carlson BE. Effect of specimen configuration and notch root angle on fatigue behavior of novel dissimilar resistance spot welds of AA5754 to HSLA steel. Procedia Struct Integr. 2022;37:351-358.
33. Guzanová A, Brezinová J, Varga J, Džupon M, Vojtko M, Janoško E, Viňáš J, Draganovská D, Hašuľ J. Experimental study of steel–aluminum joints made by RSW with insert element and adhesive bonding. Materials. 2023;16(2):864.
34. Liu H, Zhu Y, Tian Y, Wei F, Zhou Y, Zhu Z. Study on mechanical properties and failure mechanism of medium manganese TRIP steel/DP590 dissimilar steel resistance spot welding joint. Mater Res. 2023;26.
35. Manladan SM, Ramesh S, Luo Z. Lap-shear performance of aluminum alloy 5754 and 420 martensitic stainless steel resistance spot weld. In: AIP Conference Proceedings. 2023 Jan;2643(1):050010. AIP Publishing LLC.
36. Qiu R, Li J, Shi H, Yu H. Characterization of resistance spot welded joints between aluminum alloy and mild steel with composite electrodes. J Mater Res Technol. 2023;24:1190–1202.
37. Shi L, Xue J, Kang J, Amirkhiz BS, Haselhuhn AS, Carlson BE. Tensile and fatigue behaviour of novel dissimilar resistance spot welds of AA5754 to steels: interplay of intermetallic layer, weld nugget diameter and notch root angle. J Mater Res Technol. 2023;22:1737–1752.
38. Winnicki M, Małachowska A, Korzeniowski M, Jasiorski M, Baszczuk A. Aluminum to steel resistance spot welding with cold sprayed interlayer. Surf Eng. 2018;34(3):235–242.
39. Chen N, Wang HP, Carlson BE, Sigler DR, Wang M. Fracture mechanisms of Al/steel resistance spot welds in coach peel and cross tension testing. J Mater Process Technol. 2018;252:348–361.
40. Chen J, Feng Z, Wang HP, Carlson BE, Brown T, Sigler D. Multi-scale mechanical modeling of Al-steel resistance spot welds. Mater Sci Eng A. 2018;735:145–153.
41. Ibrahim I, Ito R, Kakiuchi T, Uematsu Y, Yun K, Matsuda C. Fatigue behaviour of Al/steel dissimilar resistance spot welds fabricated using Al–Mg interlayer. Sci Technol Weld Joining. 2016;21(3):223–233.
42. Penner P, Liu L, Gerlich A, Zhou Y. Dissimilar resistance spot welding of aluminum to magnesium with Zn-coated steel interlayers. Weld J. 2014;93(6):225s–231s.
43. Wan Z, Wang HP, Wang M, Carlson BE, Sigler DR. Numerical simulation of resistance spot welding of Al to zinc-coated steel with improved representation of contact interactions. Int J Heat Mass Transfer. 2016;101:749–763.
44. Sun D, Zhang Y, Liu Y, Gu X, Li H. Microstructures and mechanical properties of resistance spot welded joints of 16Mn steel and 6063-T6 aluminum alloy with different electrodes. Mater Des. 2016;109:596–608.
45. Sun M, Niknejad ST, Gao H, Wu L, Zhou Y. Mechanical properties of dissimilar resistance spot welds of aluminum to magnesium with Sn-coated steel interlayer. Mater Des. 2016;91:331–339.
46. Sun M, Niknejad ST, Gao H, Wu L, Zhou Y. Mechanical properties of dissimilar resistance spot welds of aluminum to magnesium with Sn-coated steel interlayer. Mater Des. 2016;91:331–339.
47. Hu, S., Haselhuhn, A.S., Ma, Y., Li, Y., Carlson, B.E. and Lin, Z., 2021. Sensitivity of dissimilar aluminum to steel resistance spot welds to weld gun deflection. J Manuf Process. 68, pp.534–545.
48. Hayat F. The effects of the welding current on heat input, nugget geometry, and the mechanical and fractural properties of resistance spot welding on Mg/Al dissimilar materials. Mater Des. 2011;32(4):2476–2484.
49. Li Y, Zhang Y, Bi J, Luo Z. Impact of electromagnetic stirring upon weld quality of Al/Ti dissimilar materials resistance spot welding. Mater Des. 2015;83:577–586.
