Skip to main content
Article thumbnail
Location of Repository

Effect of aluminium sheet surface conditions on feasibility and quality of resistance spot welding

By Li Han, Martin Thornton, Douglas Boomer and Mike Shergold


A study investigating the effect of sheet surface condition on resistance spot welding (RSW) of aluminium has been carried out. This concentrates on two automotive aluminium alloys; AA5754 and AA6111, used for structural and closure applications respectively. The results show the marked effect that surface condition can have on the RSW process. For AA5754 sheet incomplete removal of a ‘disrupted surface layer’ prior to surface pretreatment is shown to have a detrimental effect on the RSW process. The solid wax lubricant used to assist metal forming leads to unpredictable changes in contact resistance, and consequently affects the process stability. For AA6111 closures the final surface topography can influence the RSW process. Standard ‘mill’ and electro-discharge textured (EDT) finish sheet surfaces were examined and preliminary results suggest that both are suitable for welding. The successful application of RSW of aluminium sheet requires careful consideration of the sheet surface condition. This requires close collaboration between material suppliers and automotive manufacturers

Topics: TJ, TL
Publisher: Elsevier SA
Year: 2010
OAI identifier:

Suggested articles


  1. (1994). A fresh look at resistance spot welding of aluminium automotive components, SAE doi
  2. (2003). A new approach for robust high productivity resistance spot welding of aluminium”, doi
  3. (2001). An Aluminum Liftgate Designed for HighVolume Production.
  4. (1991). Application of all aluminium automotive body for Honda NSX, doi
  5. (2000). Balancing conflicting property requirements in the development of AA6016 automotive closure sheet. 2 nd International symposium of aluminium surface science and technology.
  6. (2006). Comparison of self-pierce riveting, resistance spot welding and spot friction joining for aluminium automotive sheet, SAE doi
  7. (2005). Developments towards high-volume resistance spot welding of aluminium automotive sheet component, Lean Weight Vehicle Conference.
  8. (2007). Effects of Sheet Surface Conditions on Electrode Life in Resistance Welding Aluminum, Welding journal,
  9. (1992). Electrical discharge texturing”, doi
  10. (1997). How to Weld Bond Aluminium with Structural Adhesives”, doi
  11. (1984). Improvement on the resistance spot weldability of aluminium body sheet, SAE doi
  12. (2007). Influence of lubricants on electrode life in resistacne spot welding of aluminium alloys, Welding research,
  13. (2006). Jaguar uses castings, extrusions to reduce parts count in new sports car, doi
  14. (2000). Joining techniques for aluminium spaceframes used in automobiles, Part II – adhesive bonding and mechanical fasteners, doi
  15. (1995). Light alloys, Third edition, doi
  16. (1994). Optimizing resistance spot welding on aluminium alloy 6111 auto body sheet, SAE doi
  17. (2000). Recent development in aluminium alloys for the automotive industry, doi
  18. (1985). Resistance welding: Measurement of the transition resistance in aluminum materials.
  19. (1996). Riview of surface pretreatment fro aluminium alloys,
  20. (2002). Self-pierce riveting–a new way for joining structures, ASME,
  21. Some surface factors that affect the spot welding of aluminium,
  22. (2000). The 2 nd generation Audi space frame of the A2: A trendsetting all-aluminium car body concept in a compact class car, FISITA World automotive congress,
  23. (2008). The Application of Resistance SpotWelding to High Volume Aluminium Automobile Manufacture,
  24. (1998). The effect of surface roughness, oxide file thickness and interfacial sliding on the electrical contact resistance of aluminium, doi
  25. (1980). The surface state and weldablity of aluminium alloys, doi
  26. (2005). Trends in aluminium resistance spot welding for the auto industry,
  27. Tribology,
  28. (1984). Understanding the process mechanisms is key to reliable resistance spot welding aluminium auto body components, doi

To submit an update or takedown request for this paper, please submit an Update/Correction/Removal Request.