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The effects of electrode surface roughness and force on the resistance spot weldability and sticking of the electrode during resistance spot welding (RSW) of aluminum 6061-T6 alloy were investigated. RSW was carried out using an as-received electrode and an abraded electrode polished with sandpaper, and the nugget size and properties such as tensile shear strength and hardness of the resulting welds were investigated at two different electrode forces. In addition, a continuous RSW process was performed on the alloy to observe the effect of the electrode surface roughness on electrode sticking. When RSW was performed using the abraded electrode, which had a rough surface, the contact resistance decreased because of the effective removal of the oxide film from the surface of the aluminum alloy; consequently, the heat generated by the resistance on the surface was reduced. In addition, the growth rate of the weld nuggets formed with the abraded electrode in the thickness direction was lower than that of the nuggets formed with the as-received electrode, and the sticking of the abraded electrode was comparatively less. Also, the influence of the electrode force on the sticking of the electrode was greater in the case of the as-received electrode.

Effects of Surface Roughness and Force of Electrode on Resistance Spot Weldability of Aluminum 6061 Alloy