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Duplex stainless steel is an ideal candidate in the automotive sector leading to a significant weight reduction and enhancement in product safety. In the present work, two major influencing process parameters i.e. welding current and welding time have been considered to investigate the mechanical and metallurgical performance of resistance spot welded duplex stainless steel. Other important process parameters, such as electrode force, squeeze time and hold time have been kept constant throughout the process. Results show that tensile shear strength (TSS) increases with an increase in welding current as well as welding time due to more amount of heat generation at interface. However, excessive value of both results in the expulsion of weld material which significantly alters the nugget diameter and cause decrease in TSS. Moreover, the failure mode is changed from interfacial failure (IF) mode to pull-out failure (PF) mode at the higher value of welding current and time. Microstructural observation reveals that the fusion zone (FZ) is consisted of columnar grain structure, whereas heat affected zone (HAZ) contains equiaxed grain structure. Furthermore, the phase balance of austenite and ferrite is completely disturbed in the FZ and HAZ.

AISI 2205 DSS for body-in-white automotive structure: effect of welding current and time on the performance of spot welded joint