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Effect of aluminium sheet surface conditions on feasibility and quality of resistance spot welding

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Han, Li, Thornton, Martin, Boomer, Douglas and Shergold, M.. (2010) Effect of aluminium sheet surface conditions on feasibility and quality of resistance spot welding. Journal of Materials Processing Technology, Vol.210 (No.8). pp. 1076-1082. ISSN 0924-0136

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Abstract

A study investigating the effect of sheet surface condition on resistance spot welding (RSW) of aluminium has been carried out. This concentrates on two automotive aluminium alloys; AA5754 and AA6111, used for structural and closure applications respectively. The results show the marked effect that surface condition can have on the RSW process. For AA5754 sheet incomplete removal of a ‘disrupted surface layer’ prior to surface pretreatment is shown to have a detrimental effect on the RSW process. The solid wax lubricant used to assist metal forming leads to unpredictable changes in contact resistance, and consequently affects the process stability. For AA6111 closures the final surface topography can influence the RSW process. Standard ‘mill’ and electro-discharge textured (EDT) finish sheet surfaces were examined and preliminary results suggest that both are suitable for welding. The successful application of RSW of aluminium sheet requires careful consideration of the sheet surface condition. This requires close collaboration between material suppliers and automotive manufacturers.

Item Type: Journal Article
Subjects: T Technology > TJ Mechanical engineering and machinery
T Technology > TL Motor vehicles. Aeronautics. Astronautics
Divisions: Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Faculty of Science > Engineering
Library of Congress Subject Headings (LCSH): Aluminum -- Welding, Electric welding -- Research, Joints (Engineering) -- Research, Surfaces (Technology)
Journal or Publication Title: Journal of Materials Processing Technology
Publisher: Elsevier SA
ISSN: 0924-0136
Official Date: 1 June 2010
Volume: Vol.210
Number: No.8
Number of Pages: 7
Page Range: pp. 1076-1082
Identification Number: 10.1016/j.jmatprotec.2010.02.019
Status: Peer Reviewed
Publication Status: Published
Access rights to Published version: Open Access
Funder: Advantage West Midlands (AWM), Novelis, Jaguar PLC
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URI: http://wrap.warwick.ac.uk/id/eprint/3310

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