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Influence of working condition fluctuation on resistance spot welding of aluminum alloy and steel
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Jiaxuan CHEN1, 2, Shanqing HU3, Zhuoran LI1, 2, Qingbang HU4, Yunwu MA1, 2, Yujun XIA1, 2, Yongbing LI1, 2
Journal of Mechanical Strength | 2025, 47(9) : 80 - 89
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Journal of Mechanical Strength | 2025, 47(9): 80-89
Influence of working condition fluctuation on resistance spot welding of aluminum alloy and steel
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Jiaxuan CHEN1, 2, Shanqing HU3, Zhuoran LI1, 2, Qingbang HU4, Yunwu MA1, 2, Yujun XIA1, 2, Yongbing LI1, 2
Affiliations
  • 1.State Key Laboratory of Mechanical Systems and Vibration, Shanghai Jiao Tong University, Shanghai 200240, China
  • 2.Shanghai Key Laboratory for Digital Manufacturing of Thin-Walled Structures, Shanghai Jiao Tong University,Shanghai 200240, China
  • 3.Institute of Materials, China Academy of Engineering Physics, Mianyang 621900, China
  • 4.Manufacturing Engineering (ME) Center, Geely Automobile Group Co., Ltd., Ningbo 315300, China
Published: 2025-09-15 doi: 10.16579/j.issn.1001.9669.2025.09.007
Outline
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Under the background of automotive lightweighting, the use of resistance spot welding to achieve effective connection of aluminum to steel structures is an unremitting pursuit. However, in actual welding production, fluctuation of working conditions occur frequently, seriously affecting the quality of weld points. Firstly, the resistance spot welding process was adopted to connect aluminum alloy and low-carbon steel plates. The influences of different inclination angles, plate gaps,and fluctuations in cooling water flow conditions on the resistance spot welding of aluminum-steel were investigated. Then,the quality of the weld points was evaluated by comparing the diameter and thickness of the nugget, the thickness of the intermetallic compound, the coach peel performance, as well as the fracture mode. The research results show that an increase in the inclination angle and the gap between the plates within a certain range, as well as a decrease in the cooling water flow within a certain range, will both reduce the quality of the weld points. Therefore, they should be avoided as much as possible in actual production. The results of this study provide a theoretical basis and practical guidance for optimizing the resistance spot welding process of aluminum to steel.

Resistance spot welding  /  Working condition fluctuation  /  Intermetallic compound  /  Coach peel performance  /  Fracture mode
Jiaxuan CHEN, Shanqing HU, Zhuoran LI, Qingbang HU, Yunwu MA, Yujun XIA, Yongbing LI. Influence of working condition fluctuation on resistance spot welding of aluminum alloy and steel[J]. Journal of Mechanical Strength, 2025 , 47 (9) : 80 -89 . DOI: 10.16579/j.issn.1001.9669.2025.09.007
Funding
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  • National Key Research and Development Program(2023YFB4707100)
  • National Natural Science Foundation of China(52305432)
Appendix
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Year 2025 volume 47 Issue 9
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59
32
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Article Info
doi: 10.16579/j.issn.1001.9669.2025.09.007
  • Receive Date：2025-05-30
  • Online Date：2026-03-20
  • Published：2025-09-15
Article Data
Affiliations
History
  • Received：2025-05-30
Funding
National Key Research and Development Program(2023YFB4707100)
National Natural Science Foundation of China(52305432)
Affiliations
    1.State Key Laboratory of Mechanical Systems and Vibration, Shanghai Jiao Tong University, Shanghai 200240, China
    2.Shanghai Key Laboratory for Digital Manufacturing of Thin-Walled Structures, Shanghai Jiao Tong University,Shanghai 200240, China
    3.Institute of Materials, China Academy of Engineering Physics, Mianyang 621900, China
    4.Manufacturing Engineering (ME) Center, Geely Automobile Group Co., Ltd., Ningbo 315300, China

Corresponding:

HU Shanqing, E-mail：
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表12种不同金属材料的力学参数
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小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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