Resistance Element Welding Between Magnesium Alloy and Aluminum Alloy Using an Al Rivet

Resistance element welding is performed using AZ31B magnesium alloy (MA) as the upper plate and A6061 aluminum alloy (AA) as the lower plate. Rivets with leg diameters of 4, 6, 8, and 10 mm are utilized as the element. The impact of welding current (WC) and welding time (WT) on the tensile shear load (TSL) of the joint is investigated, in addition to conducting an analysis of the microstructure of joint. The TSL of the joint reached the maximum value of ≈6.99 kN when a rivet with a leg diameter of 10 mm is used under the conditions of a WC of 35 kA, a WT of 120 ms, and an electrode pressure of 4.8 kN. The results reveal that a reaction layer developed at the interface between the AA rivet leg and the MA upper plate and it comprises a single row of Al 12 Mg 17 grains that are elongated parallel to the interface plane.