Single-step joining of dissimilar material combinations between ultra-high-strength steels and high-strength aluminium alloys with sufficient mechanical joint properties by using conventional resistance spot welding equipment has not been reported yet. In this research paper, a novel single-step joining technology, so-called self-penetrating resistance element welding, is introduced. First, the motivation for this novel joining technology, the state of the art in joining, and the process characteristics are presented. In the results section, the welding rivet geometry is first determined using forming simulations and validated by head tensile tests. Followed by the description of the welding process and its characteristics, the mechanical joint properties are reported. The results show that a numerically optimised welding rivet geometry can guarantee sufficient joint strength. By this welding rivet geometry, a thermally assisted penetration of aluminium and therefore welding to steel is possible with and without adhesive. Furthermore, it is shown that the welding process can be designed by means of simulations. Finally, the shear tensile tests prove that an overall sufficient joint strength is ensured.

尚未报道过使用常规的电阻点焊设备对具有足够机械连接性能的超高强度钢和高强度铝合金之间的异种材料组合进行单步连接的情况。在这篇研究论文中，介绍了一种新颖的单步连接技术，即所谓的自穿透电阻元件焊接。首先，介绍了这种新颖的连接技术的动机，连接的最新技术以及工艺特性。在结果部分中，首先使用成形模拟确定焊接铆钉的几何形状，然后通过头部拉伸试验对其进行验证。接下来是对焊接工艺及其特性的描述，并报告了机械接头性能。结果表明，数值优化的焊接铆钉几何形状可以保证足够的接头强度。通过这种焊接铆钉的几何形状，可以在有或没有粘合剂的情况下以热辅助方式渗透铝，从而可以焊接到钢上。此外，示出了可以通过模拟来设计焊接过程。最后，剪切拉伸试验证明可以确保总体上足够的接合强度。