Abstract
The corrosion behaviour of lightweight aluminium/steel joints formed through resistance spot welding with multi-ring domed electrodes was investigated. A detailed examination of the RSW joint between 6016 aluminium and DP780 galvanised steel was conducted using electrochemical corrosion tests in a 3.5% NaCl solution and spray acceleration tests. The bonding process involved the formation of an interfacial Fe–Al intermetallic layer, with oxide inclusions near the aluminium nugget. Unlike the interfacial intermetallic layer, microcracks and Si-rich regions at the aluminium-side interface front were found to be particularly vulnerable to corrosion during salt spray exposure. This study demonstrates that the microstructure and interface oxides are key factors affecting corrosion resistance of the joint nugget and provides insights into optimising the RSW process.
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