ARCHIVES OF CIVIL AND MECHANICAL ENGINEERING

Vol. X

2010

No. 1

Using resistance spot welding for joining

aluminium elements in automotive industry
A. AMBROZIAK, M. KORZENIOWSKI
Wrocaw University of Technology, ukasiewicza 5, 50-371 Wrocaw, Poland.
The aluminium alloys are more frequently used in automotive industry especially as an alternative
material for car-bodies.
In this article the comprehensive summary concerning technology of resistance spot welding of aluminium alloys was presented. The welding schedules, electric parameters of welding, electrodes materials
and electrodes life time by resistance spot welding aluminium were described.
Few examples directly from automotive industry were presented and advantages of aluminium as
a material for some vehicle parts were also discussed.
Keywords: resistance spot welding of aluminium alloys, automotive industry

1. Introduction
Aluminium as a pure metal is known since the beginning of the 18th century. It was
extracted and isolated by Christian Oersted in 1825. Although the massive production
method of extraction aluminium from its ore bauxite was discovered in the second half
of 18th the century, the process in its basis is has been using until today. It consists of
2 stages: the first one extraction of Al2O3 (aluminium oxide) from the ore, the second
one the electrolytic reduction of Al2O3 in high temperature bath of Na3AlF6 [1].
The mechanical strength of pure aluminium is relatively weak; this is the reason
that for constructional purposes is used rarely. To increase the mechanical strength of
pure aluminium some alloy elements are added, mainly silicon, magnesium, copper
and zinc.
Currently, aluminium alloys are common used in aircraft, military industry and
automotive industry. It is possible to join aluminium most of the known welding
methods by using conventional equipment.
Today, the automotive industry struggles with weight problem, which should be
taken into account by the engineers [2]. The demands of customers regarding safety
and luxury cause the thicker sheets and components for more responsible parts of
body like frame, chairs, reinforcement must be applied. This is the reason some parts
of body are replaced by light materials (like aluminium and magnesium alloys [3]),
which mechanical properties are similar or even better than steel.

A. AMBROZIAK, M. KORZENIOWSKI

The newest predictions estimate, that increasing use of light non-iron alloys like
aluminium alloys decrease the total weight of vehicle. What is more, otherwise than in
case of steel aluminium, and aluminium alloys are corrosion-resistance.

2. Properties of aluminium
Aluminium and its alloys are a silvery white which have density from 2.6 g/cm3 up
to 3.0 g/cm3.
Although pure aluminium is light metal, the mechanical strength of some its alloys
exceeds the strength of mild steel. It has high thermal and electrical conductivity, high
reflectivity to both heat radiation and the light. It is non-magnetic material. The characteristic feature of aluminium is that there is no colour change during heating.
The melting temperature of pure aluminium is 660 C (1220 F). Aluminium alloys
have approximately melting range from 480 C (900 F) up to 660 C (1200 F), it depends of the composition of alloying components.
Both high thermal conductivity and high electrical conductivity cause, the resistance spot welding requires welding higher current and shorter welding time (as compared to steel). What is more, the welding parameters must be controlled more precisely.
One of the disadvantages during welding aluminium is its oxide film Al2O3
(known sometimes as alumina), which appears rapidly on the surface of aluminium.
Its melting temperature exceeds 2000 C, so it should be removed chemically or mechanically before welding. The second disadvantage is high electrical conductivity.
From the other hand aluminium oxide protects the surface of aluminium before the
corrosion. This is the reason any coatings need to be used.
Physical properties of aluminium alloys and mild steel are presented in Table 1.
Table 1 . Physical properties of mild steel and aluminium alloys [4]

Mild steel
Aluminium
alloys

Melting
temperature
[C]

Electrical
Conductivity
106 [Sm]

Thermal
conductivity
[W/cmK]

1560

510

0.32 0.66

Coefficient
of thermal
expansion
10-6 [1/K]
11.4

480 660

14.337.7

1.22.37

2223

Density
[g /cm3]
7.8
1.73.0

It was mentioned the pure aluminium is not used as a material for mechanical constructions. To make it stronger alloying ingredients as copper, zinc, manganese, magnesium, silicon are applied.
The designation of aluminium alloys indicates directly the form and composition of
alloys and main alloying elements. The first digit identify the main alloying elements,
the last three the composition of alloy. There are two forms of aluminium alloys:
wrought and casting alloys. For automotive body sheet the wrought alloys mainly

Using resistance spot welding for joining aluminium elements in automotive industry

5xxx and 6xxx series are used, so it will be taken into account. Designation of
wrought alloys, the main alloying elements, production forms and application are presented in Table 2 [1], [4].
Table 2. Designation, product form, and application of aluminium alloys
Aluminium wrought
Product form
Application
alloy designation
Pure aluminium
Foil, rolled plate, extruPackaging and foil, roofing, cladding, low1XXX*
sions
strength corrosion resistant vessels and tanks
Highly stressed parts, aerospace, structural
2XXX
Rolled plate and sheet,
items, heavy duty forgings, heavy goods
(Al-Cu)
extrusions, forgings
vehicle wheels, cylinder heads, pistons
Packaging, roofing and cladding, chemical
3XXX
Rolled plate and sheet
drums and tanks, process and food handling
(Al-Mn)
extrusions, forgings
equipment, vehicles
Filler metals, cylinder heads, engine blocks,
4000 series
Wire, castings
valve bodies, architectural purposes
(Al-Si)
Cladding, vessel hulls and superstructures,
Rolled plate and sheet,
5000 series
structural members, vessels and tanks, vehicles,
extrusions, forgings, tub(Al-Mg)
automotive body sheet
ing, piping
High-strength structural members, vehicles,
Rolled plate and sheet,
6000 series
rolling stock, marine applications, architectural
extrusions, forgings,
(Al-Si-Mg)
applications, automotive body sheet
tubing, piping
High-strength structural members, heavy
7000 series
Rolled plate and sheet,
section aircraft forgings, military bridging,
(Al-Zn)
extrusions, forgings
heavy goods vehicle
* In case of pure aluminium the last two digits indicate the minimum purity of aluminium (e.g., 1060 is
99.60% Al minimum).

3. Applying aluminium alloys in automotive industry

Aluminium is the ideal material for future development of designing car bodies.
The main purpose for applying aluminium is decreasing total weight of vehicle by assuming, that safety, and strength of constriction will be at least the same. What is
more, applying aluminium as an alternative material involves the aspect of engineload reduction and decreasing the consumption of gasoline and the reduction of exhaust emission.
Furthermore, the costs of exploitation of vehicle concerning breaks, tries, bearings
and many others will decrease as well.
It was proved that the reduction the total mass of vehicle of 10% involves saving
68% of gasoline. Decreasing the total weight of each 100 pound causes savings 3.4
5.3 per 1000 miles [5].
Aluminium is fully recyclable. Its scarp can be easy recovered. Moreover, it can be
recycled again and again without changing quality. Its properties will be the same as
aluminium obtained from its ore. Even now, approximately 6070% aluminium used

A. AMBROZIAK, M. KORZENIOWSKI

in vehicles (engine, body, wheels, etc.) comes from recycling. The cost of recycling of
aluminium is considerably lower than steel due to lower than in case of steel the energy consumption.
There is one disadvantages connected with recycling of aluminium alloys. The
different alloys must be selected and they cannot be mixed. It is especially important
and crucial by production of sheets.

4. Resistance spot welding

The resistance spot welding is the most popular method of joining metal sheets.
The connection arises by flowing the current and action of welding force. Heating of
joining parts during resistance welding is an effect of heat generation on electrical resistance of welding circuit according to JouleLenz law:

Q (t ) = I (t ) R dt
0

(1)

where:
Q generated heat,
I welding current,
R electrical resistance of welding circuit,
t welding time.
Scheme of resistance spot welding was shown on Figure 1.

Fig. 1. Schematic view of the spot welding process [6]

Connecting 2 or 3 parts of sheets is possible by the resistance spot welding. During

this process one or more welding joints can be obtained. It depends of applied welding
machines.
Resistance spot welding (RSW) is the most popular method of joining parts in
automotive industry, which prefers this joining method because it is low-cost, rapid,
simply and easy for automation. Over 90% of spot welds of all over the world are performed by automotive industry [7]. It was estimated, that each body car and its com-

Using resistance spot welding for joining aluminium elements in automotive industry

ponents contains over 50 hundred spot welds. For many years the material the carbodies consisted of was mild steel, with or without galvanized layers. Now, the engineers try to find alternative light-materials: aluminium and magnesium alloys.
Unconformities which can appear in spot welds cause the spot welds can have less
strength and can lead into total destruction of manufacturing parts of cars bodies.
The typical unconformities of spot welds are [8]:
cold weld,
small-diameter nugget,
bad shape of welding nugget,
cracks inside/around welding nugget,
deep indentation of welding electrodes in sheets.

Fig. 2 Typical flaws in spot welding joints [9]

5. Resistance spot welding of aluminium

The weldability of aluminium alloys used by joining car bodies is very good but
some conditions and rules must be applied. Resistance Spot Welding of aluminium
and its alloys involves applying high power welding guns because welding current
must be 23 times higher than in case of steel but the welding time is 1/3 weld time of

10

A. AMBROZIAK, M. KORZENIOWSKI

steel. The main of that is 3 times higher than in case of steel its thermal and electrical
conductivity. It means the electric parameters (current and voltage) must be controlled
more precisely in narrower window of time [10].
Sometimes the welding guns using for welding steel has not enough power to ensure required welding current, thus the sources of power are often designed for resistance spot welding of aluminium.
The comparison the typical RSW parameters for 1.0+1.0 mm mild steel and aluminium sheets are included in Table 3.
Table 3. RSW parameters for 1.0+1.0 mild steel and aluminium sheets
Welding time
Material
Welding current [kA]
[periods for 50 Hz]
Mild steel
11
8
Aluminium alloy
25
4
5xxx, 6xxx series

Welding Force
[kN]
2.7
2.5

6. Electrodes for resistance welding aluminium

An ideal electrodes material for RSW of aluminium should have high thermal and
electrical conductivity and high hardness as well. Moreover it shouldnt tend to make
alloys thus it is very difficult to find a compromise. The pure electrolytic copper has
a conductivity 100% IACS (58 MSm), however its hardness is relativity low (considerably below 100HV) and its tendency to alloying with aluminium is very high.
The main problem connected with electrodes by Resistance Spot welding of aluminium and its alloys is relatively short time of life of electrodes [11]. It can be a crucial problem especially by massive production. The rapid deterioration of tips surface
is the result of high pressure, high temperature and alloying process during welding
[11], which directly involves pickup effect, electrode alloying with aluminium, pitting
effect and cavitations. Thus the quality of spot-welds rapidly decreases. The comprehensive numerical and experimental study, concerning pitting effect and its influence
on spot-welds quality of aluminium-alloys joints were described in [1214].
The alloying effect causes increasing resistance of contact tip-sheet. This is the reason the heat is generated in tip-sheet layer, instead sheet-sheet. To ensure the better
contact between electrode and worksheet the lubricants are applied. It was investigated,
that some metalworking lubricants extended the electrodes life-time and directly led to
reduction alloying effect and concurrently pitting and pickup effect [15].
To avoid high costs of electrodes materials replaceable caps are used and also
cleaning after at least 20 spot-welds is required as well.
It was proved, that increasing hardness of electrodes reduces mushrooming of
electrodes. To achieve higher hardness pure copper is alloyed by zirconium, cadmium,
chromium and also dispersion hardened with aluminium oxide is used. It was investigated that using some special copper alloys especially alloyed by gold [1617]. This
way 5 times longer time of life can be achieved.

Using resistance spot welding for joining aluminium elements in automotive industry

11

Recommended by resistance welders manufacturing association electrodes for spot

welding aluminium are group A class 1 alloys.
Group A class 1 alloys have the highest electrical conductivity thus are the best for
welding pure aluminium worksheets. For Al-Mg and Al-Mg-Si alloys higher hardness
is required so, electrodes A class 2 can be used. [4]. Electrodes materials properties
were presented in Table 5.
Table 4. Resistance welding electrodes materials [4]
Copper
Properties
alloy class
high conductivity 95100% IACS
A1
(ca. 58 MSm)
Hardness: 130170 HV, electric
A2/1
conductivity: 80% IACS (43 MS/m),
softening temperature: 450500C
A2/2
Hardness: 160240 HV, electric
A3/1
conductivity: 50% IACS (23 MS/m),
softening temperature: over 500C

Application
resistance welding of aluminium
and aluminium alloys
resistance welding of mild steel, brass,
aluminium alloys
resistance welding of stainless
and austenitic stainless steel

The properties of copper alloys using for electrodes in automotive industry are presented in Table 5. In the columns shaded on grey, properties of copper alloys for resistance spot welding of aluminium are mentioned.
Table 5. Composition, physical and mechanical properties of electrodes copper alloys [18]
Designation of alloy
CRM16X
BICOP
CB4
Cr: >0.4%
Co: 2.2%
Composition
Al: 0.6%
Zr: 0.30.15
Be: 0.5%
Hardness [HB]
160
150
240260
Conductivity
76 46
85
>43
[% IACS]
Tensile strength MPa
480
430
700
Table 6. Electrodes diameter and recommended nugget size related to sheet thickness for mild steel
and aluminium alloys series 1xxx, 3xxx, 5xxx and 6xxx [1]
Electrode diameter
Electrode dome
Nugget size
Thickness of
[mm]
radius [mm]
[mm]
worksheets
Mild
Mild
Mild
[mm]
Al
Al
Al
Steel
Steel
Steel
0.5
16
3.5
50
65
2.5
2.5
0.8
16
4.5
50
74
3.5
3.6
1.0
16
5
100
80
4.0
4.6
1.3
16
6
100
87.5
4.5
5.1
1.6
16
6
100
98
5.2
5.8
2.0
22
7
150
110
5.7
6.6
2.5
22
8
150
125
6.5
7.1
3.2
22
9
150
146
7.1
7.6

12

A. AMBROZIAK, M. KORZENIOWSKI

To maintain correctly tips condition electrodes efficient cooling must be ensured.

The coolant flow rate should be of 510 litres per minute (more than in case of steel).
Its temperature should be ca. 20 C in inlet area and outlet area 30 C. Inlet channel
should be carried as close to the tips as possible by the distance 1220 mm from outlet
channel.
In Table 6 technological parameters of electrodes for welding aluminium alloys
and mild steel are presented. Please notice that diameter of tips and dome radius is
bigger for aluminium alloys.

6. Conclusions
According to the newest studies, automotive industry tends to use light alloys like
aluminium and magnesium alloys. Companies more often use aluminium as an alternative material for vehicle body. The most popular method of joining body sheets is resistance spot welding. Aluminium and its alloys series 5xxx and 6xxx can be connected by
this technique. It requires high power welding gun and precocious steering of current
and time. The aspects of rapid deterioration of tips must be taken into account.
References
[1] Mathers G.: The welding of aluminium and its alloys, Woodhead Publishing Limited, Cambridge, England, 2002.
[2] Carle D., Blount G.: The suitability of aluminium as an alternative material for car bodies, Materials and Design, Vol. 20, No. 5, 1999, pp. 267272.
[3] Kawalla, R., Lehmann, G., Ullmann, M.: Magnesium semi-finished products for vehicle construction, Archives of Civil and Mechanical Engineering, 2008, Vol. 8, No. 2, pp. 93101.
[4] Welding Handbook, Vol. 3, 8th Edition, American Welding Society, 1992.
[5] The Aluminium Association, Inc.: Aluminium industry roadmap for the automotive market: enabling technologies and challenges for body structures and closures, May, 1999.
[6] Chertov, A.M., Maev R.G.: A one-dimensional numerical model of acoustic wave propagation in a multilayered structure of a resistance spot weld, ultrasonics, ferroelectrics
and frequency control, Vol. 52, Issue 10, pp. 17831790.
[7] Papkala H., Pietras A., Zadroga L.: Zgrzewanie rezystancyjne punktowe blach ocynkowanych, Przegld Spawalnictwa, No. 57, 2004, pp. 5157.
[8] Ambroziak A., Korzeniowski M., Kustron P.: Quality control of spot welds the challenge for automotive industry, inynieria produkcji. Wiedza wizja programy ramowe,
Pod red. E. Chlebusa, Wrocaw, Oficyna Wydaw. PWroc., 2006, pp. 359366.
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[10] Aloca Inc.: Spinella D.J., Brockenbrough J.R., Fridy J.M.: Trends in aluminium resistance spot welding for the auto industry, Vol. 84, No. 1, 2005, pp. 34 40.
[11] Li Z., Hao C., Zhang J., Zhang H.: Effects of sheet surface conditions on electrode life in
resistance welding aluminium, Supplement to Welding Journal, Vol. 86, No. 4, 2007,
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Using resistance spot welding for joining aluminium elements in automotive industry

13

[12] Lum I., Fukumoto S., Birdo E., Boomer D.R., Zhou Y.: Electrode pitting in resistance spot
welding of aluminium alloy 5182, Metallurgical and Materials Transactions, Vol. 35, No. 1,
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[13] Zhou Y., Fukumoto S., Peng J., Ji C.T., Brown L.: Experimental simulation of surface
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Science and Technology, Vol. 20, No. 10, 2004, pp. 12261232.
[14] Chang B.H., Zhou Y., Lum I., Du D.: Finite element analysis of effect of electrode pitting
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Joining, Vol. 10, No. 1, 2005, pp. 6166.
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electrode life in resistance spot welding of aluminium alloys, Welding Journal, Vol. 86, No. 3,
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[16] Kumagai M., Sano H.: Effect of Cu-Ag-O electrode on resistance spot welding of aluminium alloy sheet, JASE Review, Vol. 17, No. 1, 1996, pp. 8383.
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Zastosowanie zgrzewania oporowego do zgrzewania
konstrukcji w przemyle motoryzacyjnym
Stopy aluminium s coraz czciej stosowane jako materia alternatywny do budowy elementw karoserii samochodowych.
W artykule opisano technologiczne problemy podczas zgrzewania oporowego punktowego
materiaw ze stopw aluminium (gwnie z grupy 5xxx i 6xxx), skupiajc si na parametrach
elektrycznych zgrzewania, materiaach na elektrody oraz czasie ich ycia.
Przedstawiono zalety zastosowania materiaw ze stopw aluminium, jako materiau, z ktrego mog by wykonywane niektre czci w pojazdach samochodowych.