In this study, taking six-series aluminium alloy and DC06 galvanised steel resistance spot welding as the object of study, the impacts of the electrode cap shape and process parameters on the joint welding performance were analysed, and the electrode cap was optimised. The optimised process parameters involved the use of spherical asymmetric electrodes and a pre-welding preheating step for zinc extrusion treatment, followed by a double pulse for welding. The optimal parameters resulted in an aluminium/steel spot welding head average pull shear failure load of 2858.7 N and aluminium/aluminium spot welding head failure force of 2436 N, reaching 117.3% of its original value. The minimum force value (2253.4 N) was greater than 92.5%, and the failure section was all from the aluminium side in parent material button failure, achieving good final results.
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