Abstract
The present paper reports the resistance spot welding of steel and aluminium sheets using aluminium clad steel sheets as insert metals. Intermetallic compound layers were formed in the weld zones in direct spot welding of steel sheets to aluminium sheets. Thus, the strength of these joints was lower than that of aluminium to aluminium joints. Intermetallic compound layers were also formed at the steel/aluminium interfaces of the insert metal in welding of steel to aluminium using an insert metal sheet. However, the strength of these joints was of the same order as that of the aluminium joints. The fracture mode of these joints varied with the welding current. The suitable welding current for steel to aluminium joints varied between the values suitable for steel to steel and aluminium to aluminium joints. The fatigue strength of joints using insert metals was somewhat lower than that of the aluminium joints.
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