Improvement of the resistance spot welding and weldbonding of Al-Mg-Si alloys by

using cladding technology: An optical and mechanical characterization study

P. Bamberg, R. Seewald, A. Schiebahn, U. Reisgen, N. Precoma, M. Epperlein

1Welding and Joining Institute, RWTH University, Aachen, Pontstr. 49, 52062, DE.

The recent body in white developments within lightweight structural automotive

applications has experienced an increasing demand on the joining of aluminum alloys.
However, new challenges come along with it. For example, the resistance spot welding
(RSW) process is currently limited, regarding the suitable aluminum alloys for structural
applications. Some alloys present poor mechanical performance, despite good electric and
chemical properties (i.e. AW-1000, 3000 and 4000 series), while others, especially the heat
treatable Al-Mg-Si alloys (6000 series), may present process robustness issues, narrow
welding lobe and/or short electrode life, despite good mechanical properties. The cladding
of different aluminum alloys is currently launched from some aluminum producing
companies and possess the potential to improve the sheet weldability, whilst maintaining
the structural performance. The approach is based on the combination of a high conductive,
electric stable aluminum alloy as covering sheet, with a high strength alloy as core sheet.
The objectives of this work are the evaluation of an improved weldability of an AW-6111
(core sheet) cladded with an AW-4040 (cover sheet), by establishing a proper welding lobe
(estimated by means of the nominal and maximum welding current levels and weld spot
diameters), an analysis of the electrode erosion behavior and a characterization of the
formed microstructure. Comparisons with a pure AW-6111 aluminum sheet are done. In
addition, the validation of the cladded sheets RSW with one- and two-component epoxy
structural adhesives are attempted and optical and mechanical characterizations are
performed. Initial results have shown that the cladded sheets presented improved
weldability characteristics and increased the electrode service life.

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