Effect of spot welding parameters on microstructure and properties of 5182/DP780 joint

In the automotive, joining aluminum alloys and high-strength steel is crucial for vehicle lightweighting. Traditional welding methods struggle with joint embrittlement and weld nugget morphology control in steel-aluminum connections, limiting their use in automotive manufacturing. This study aims to optimize the resistance spot welding of 5182 and DP780 by novel welding electrodes and parameters. A double helix raised electrode is employed to improve heat distribution. The effects of welding current, electrode pressure, and welding time on joint morphology and properties are systematically analyzed. Enhancing production efficiency and quality in intelligent welding lines helps reduce costs and increase efficiency. The research found that using a welding current of 12 kA for 500 ms, and applying the pressure of 4.0 kN resulted in a maximum joint load of 4544 N.