Resistance spot welding (RSW) process with protective coatings on advanced high-strength steels is a challenge. An ultimate tensile strength (UTS)1500 MPa grade hot stamping sheet steel(22MnB5) with Al–Si coating was employed for the RSW process in the present study. The effects of Al–Si coating on the microstructure of RSW joints and tensile-shear fracture behaviour were investigated. Strip-like Fe-(Al,Si) cladding on the surface of nugget tongues acted as the crack source and initiated the fracture. Two types of fatigue failure mode were observed: nugget pull-out with tearing of base material (BM) and eyebrow-shaped fracture along the BM width direction, corresponding to high and low loading levels, respectively. All fatigue fracture cracks were found to be originated along the Fe-(Al,Si) strip through the heat-affected zone.
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