Abstract
Improvements in electrode life are possible when resistance spot welding coated steels, through the application of current stepping techniques. The present investigation has evaluated a number of criteria for establishing optimum rates of current increase. The most significant improvements in welding performance were obtained when the current was increased as a function of electrode tip growth. It was found that electrode softening occurred at a faster rate when current stepping, compared to welding using standard conditions. This softening was caused by recrystallisation of the base electrode material and resulted in a fast tertiary stage of electrode tip growth. The practical implications of the work are discussed.
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