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The effects of Zn-based alloys coating (Zn, Al-Zn and Al-Mg-Zn) on the bondability of steel/aluminum alloy dissimilar metals joints were evaluated, in order to achieve strength in lower welding current. In the joint with Zn-based alloys insert, the oxide film on the aluminum alloy was sufficiently removed through eutectic reaction of Zn-based alloys and aluminum. In the joint with Zn-coated steel (GI), higher welding current is necessary to discharge the zinc coating and the oxide film from the bonding interface sufficiently. The thinner aluminum plate after welding and the thick reaction layer cause the decrease of cross tensile strength in the joints with no coating steel (SPCC) and Al-Zn-coated steel. Using Al-Mg-Zn-coated steel, higher strength was achieved in a lower welding current. This is because Al-Mg-Zn-coating melted at lower temperature than Zn and Al-Zn-coating, and the removal of the coating material and the oxide film on the aluminum alloy were sufficiently performed in the lower welding current.

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Effects of Zn-Based Alloys Coating on Mechanical Properties and Interfacial Microstructures of Steel/Aluminum Alloy Dissimilar Metals Joints Using Resistance Spot Welding