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Electrode pitting in resistance spot welding of aluminum alloy 5182

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Abstract

Electrode pitting was investigated in resistance spot welding of 1.5-mm-thick sheet aluminum alloy 5182 using a medium-frequency direct-current welder and electrodes with a tip face curvature radius of 50 mm and tip face diameter of 10 mm. Detailed investigation of the metallurgical interactions between the copper electrode and aluminum alloy sheet was carried out using scanning electron microscopy/energy-dispersive X-ray spectroscopy (SEM/EDX) and X-ray diffraction (XRD). The results indicated that electrode degradation, which eventually leads to weld failure, proceeded in four basic steps: aluminum pickup, electrode alloying with aluminum, electrode tip face pitting, and cavitation. Since pitting and cavitation result from Al pickup and alloying, periodic electrode cleaning could extend electrode tip life by limiting the buildup of Al on the tip face. This work is part of the effort to improve electrode tip life in resistance spot welding of aluminum alloys for automotive applications.

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Authors and Affiliations

  1. the Department of Mechanical Engineering, University of Waterloo, N2L 3G1, Waterloo, ON, Canada

    I. Lum (Graduate Student), E. Biro (Research Engineer) & Y. Zhou (Canada Research Chair in Microjoining)

  2. the Department of Materials Science and Engineering, Faculty of Engineering, Himeji Institute of Technology, Himeji, 671-2201, Hyogo, Japan

    S. Fukumoto (Research Associate)

  3. Banbury Laboratory, Alcan International Limited, OX16 7SP, Oxfordshire, United Kingdom

    D. R. Boomer (Welding Specialist)

Authors
  1. I. Lum
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  2. E. Biro
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  3. Y. Zhou
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  4. S. Fukumoto
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  5. D. R. Boomer
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Lum, I., Biro, E., Zhou, Y. et al. Electrode pitting in resistance spot welding of aluminum alloy 5182. Metall Mater Trans A 35, 217–226 (2004). https://doi.org/10.1007/s11661-004-0122-8

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  • DOI: https://doi.org/10.1007/s11661-004-0122-8

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