Resistance spot weldability of martensitic stainless steels is impaired by the formation of brittle martensite in the fusion zone (FZ). In this paper, in situ rapid tempering via applying a second pulse current after a first melting/solidification pulse during resistance spot welding of AISI 420 martensitic stainless steel sheets was used as a pathway to enhance the toughness of the FZ. By using proper second pulse conditions, the FZ with reduced hardness can be generated which is featured by a decomposed martensitic structure with nano-sized carbide precipitations. The improved toughness as a consequence of this modified microstructure resulted in remarkable enhancement of the peak load and energy absorption of the spot welds compared to the single-pulse welds.
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