Effect of coating type on electrode degradation and its life in resistance spot welding of a low carbon steel

In this study, the degradation occurring on the surface of the electrodes used in resistance spot welding of hot dip galvanized and galvannealed low carbon steels are examined and the life of the electrodes are tested. Several characterization studies are carried out on the surface and cross-sections of CuCrZr-based electrodes, following the life tests that are carried out according to SEP 1220 standard, and it is observed that a more convex degradation surface is formed on the electrode surface used in the welding of galvannealed steel compared to the galvanized one. This geometry indicates that the induced current is more stable. Depending on the increase in the number of spots, coating type and the amount of convexity, it is determined that the phases formed on the electrode surface also differ. Although the coating type has no significant effect on the welding strength value and no significant difference is observed in the maximum current values, a longer life is determined in the electrode used for the welding of galvannealed steel. It has been identified that the dominant mechanism affecting electrode life is the coating type, which is directly related to electrode degradation.