The Effect of Welding Current and Electrode Force on the Heat Input, Weld Diameter, and Physical and Mechanical Properties of SS316L/Ti₆Al₄V Dissimilar Resistance Spot Welding with Aluminum Interlayer

• Main Authors: Iqbal Taufiqurrahman, Azlan Ahmad, Mazli Mustapha, Turnad Lenggo Ginta, Luthfi Ady Farizan Haryoko, Imtiaz Ahmed Shozib
• Format: Article
• Language: English
• Published: MDPI AG 2021-02-01
• Series: Materials
• Subjects: resistance spot welding; stainless steel 316L; Ti6Al4V alloy; mechanical properties; aluminum interlayer; welding current
• Online Access: https://www.mdpi.com/1996-1944/14/5/1129

Welding parameters obviously determine the joint quality during the resistance spot welding process. This study aimed to investigate the effect of welding current and electrode force on the heat input and the physical and mechanical properties of a SS316L and Ti₆Al₄V joint with an aluminum interlayer. The weld current values used in this study were 11, 12, and 13 kA, while the electrode force values were 3, 4, and 5 kN. Welding time and holding time remained constant at 30 cycles. The study revealed that, as the welding current and electrode force increased, the generated heat input increased significantly. The highest tensile-shear load was recorded at 8.71 kN using 11 kA of weld current and 3 kN of electrode force. The physical properties examined the formation of a brittle fracture and several weld defects on the high current welded joint. The increase in weld current also increased the weld diameter. The microstructure analysis revealed no phase transformation on the SS316L interface; instead, the significant grain growth occurred. The phase transformation has occurred on the Ti₆Al₄V interface. The intermetallic compound layer was also investigated in detail using the EDX (Energy Dispersive X-Ray) and XRD (X-Ray Diffraction) analyses. It was also found that both stainless steel and titanium alloy have their own fusion zone, which is indicated by the highest microhardness value.