Resistance Spot Weldability of Aluminum Alloy with 6 wt.% Magnesium

To ensure safety and reduce the weight of vehicles, studies are being actively conducted on different aluminum alloys that have strength higher than conventional aluminum alloys. The development of high-performance aluminum alloys through magnesium content control is underway. Research on manufacturing techniques, such as, welding for application to the car body parts of these materials is required. In this study, the resistance spot weldability of an aluminum alloy with 6 wt.% magnesium (Al-6Mg) was evaluated and compared with the commercial aluminum alloy 5052, 6061 (Al5052, Al6061). The suitable welding range of the Al-6Mg was found to have a welding current of 24 kA to 28 kA, and a similar level of Al6061. The welding heat input was almost the same for the three materials, which resulted in no difference in the diameter of the nuggets. There was no significant difference of the porosity ratio between Al-6Mg and Al5052; however, the porosity ratio of Al6061 was higher. The alloy with the highest tensile shear strength, hardness and energy absorption of a welded joint was Al-6Mg. The low porosity ratio and high hardness of the Al-6Mg alloy caused the relatively high tensile shear strength and energy absorption of the welded joint.