Electrical Resistance Spot Welding (ERSW), an ideal sheet metal welding process for automotive applications due to the excellent reproducibility and weld integrity of the process. Dual-phase steels, the next-generation advanced high strength steel is utilized in white body applications. This paper discusses the effect of current on mechanical properties and microstructural features of the weld nugget. Macrostructure reveals the optimal welding current as 5.5 kA for decent nugget formation with maximum penetration and less heat-affected zone. The nugget microstructure consists of lath and needle-like martensite structure in the iron matrix. The shear fracture test revealed nugget pull-out failure at the periphery. The results concluded the role of current in the penetration and nugget formation along with the softening effect, which corresponds to the nugget failure.
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Rajarajan et al. (2020) studied this question.
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