Abstract A 2-step schedule, consisting of a pre-cleaning step followed by a welding step, and an electrode design incorporating a multistep face geometry were developed to address issues of inclusions in the aluminum fusion zone and over thickening of intermetallic compound (IMC) layer in weld bonding of aluminum to steel. The pre-cleaning phase used a multi-pulse current to expel the adhesive from the contacting faces. The subsequent welding phase created a sound joint by growing aluminum nugget diameter while limiting IMC thickening and breaking down remaining inclusions. The multistep electrode contributed to effectiveness of the cleaning by boosting expulsion in the pre-cleaning stage. It also reduced reaction between the electrode and the outer surface of the aluminum via breaking down the oxide film of the aluminum and hence reducing contact resistance. The uncured RSWB joints, generated from the 2-step schedule together with the multistep electrode, had approximately 95% improvement in lap shear peak load compared to joints fabricated using the conventional 1-step welding schedule with a dome electrode. The cured RSWB joints achieved approximately 20% and 80% improvement in the peak load and energy absorption, respectively, in coach peel tests.

中文翻译：

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铝与钢的电阻点焊焊接工艺表和电极设计

摘要 为了解决铝熔合区中的夹杂物和金属间化合物 (IMC) 过厚的问题，开发了一个由预清洁步骤和焊接步骤组成的两步​​计划，以及包含多步面几何形状的电极设计。铝与钢的焊接粘合层。预清洁阶段使用多脉冲电流将粘合剂从接触面上排出。随后的焊接阶段通过增加铝熔核直径同时限制 IMC 增厚和分解剩余夹杂物来创建良好的接头。多步电极通过在预清洁阶段促进排出来提高清洁效率。它还通过破坏铝的氧化膜来减少电极与铝外表面之间的反应，从而降低接触电阻。与使用带有圆顶电极的传统 1 步焊接方案制造的接头相比，由 2 步方案和多步电极生成的未固化 RSWB 接头在搭接剪切峰值载荷方面提高了大约 95%。在教练剥离试验中，固化后的 RSWB 接头的峰值载荷和能量吸收分别提高了约 20% 和 80%。