Method of resistance spot welding aluminum alloy workpieces
a technology of aluminum alloy and spot welding electrode, which is applied in the direction of soldering apparatus, manufacturing tools, and maintenance of electrical components, can solve the problems of aluminum alloy sheet metal layers that can present peculiar challenges for spot welding steps, excessive heat, and contamination layer of copper-aluminum alloy to build-up or accumulate on welding electrodes, etc., to achieve the effect of reducing the amount of contamination, and facilitating the flow of electrical curren
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[0019]The methods detailed in this description resolve several challenges encountered when resistance spot welding is performed on workpieces made of an aluminum alloy to produce automotive body panels and other components. The methods also provide several improvements in the accompanying welding process. The term workpieces, as used herein, refers to metal layers that include sheets, extrusions, castings, and other pieces that are resistance spot welded together. In the described welding methods, a welding electrode is designed to have a textured weld face that exhibits a domed radiused profile with a sharp radius of curvature fairly atypical of traditional welding electrodes used in aluminum alloy applications. The textured weld face can penetrate oxide layers present on the surface of aluminum alloy workpieces, which allows for more efficient and concentrated delivery of an electric current from the weld face to the workpieces. The welding electrode can be re-dressed to preserve ...
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