Metals and Materials International

, Volume 23, Issue 3, pp 543–553 | Cite as

Nugget formation and its mechanism of resistance spot welded joints in DP600 dual-phase and DC54D ultralow carbon steel

  • Ci Li
  • Xinjian Yuan
  • Kanglong Wu
  • Haodong Wang
  • Zhan Hu
  • Xueyu Pan


Resistance spot welded joints in different configurations of DP600 and DC54D were investigated to elucidate the nugget formation process and mechanical properties of the resultant joints. Results show that, when the welding time was less than 4 cycles, the fusion zone (FZ) was not formed, but the heat-affected zone (HAZ) occurred with a “butterfly” shape. In 4 cycles, the FZ in dissimilar sheets occurred with an “abnormal butterfly” shape because of nugget shift. When the welding time increased to 14 cycles, the FZ exhibited a “bread loaf” shape and the weld shifted to “dog bones.” The nugget can be divided into three regions, namely, FZ, HAZ1, and HAZ2, and the FZ consisted of lath martensite. The micro hardness of DP600 FZ was lower than that of HAZ because of the dilution of DC54D. The failure mode of B changed from interfacial failure to plug failure during the nugget formation process. The tensile-shear load of sound weld is 6.375, 6.016, and 19.131 kN.


metals welding microstructure scanning electron microscopy (SEM) nugget formation 


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Copyright information

© The Korean Institute of Metals and Materials and Springer Science+Business Media Dordrecht 2017

Authors and Affiliations

  • Ci Li
    • 1
  • Xinjian Yuan
    • 1
  • Kanglong Wu
    • 1
  • Haodong Wang
    • 1
  • Zhan Hu
    • 1
  • Xueyu Pan
    • 2
  1. 1.College of Materials Science and EngineeringChongqing UniversityChongqingPR China
  2. 2.Body Shop, Plant 2Changan Ford Automobile Co., Ltd.ChongqingPR China

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