EXPERIMENTAL INVESTIGATION ON RESISTANCE SPOT WELDING OF ALUMINIUM ALLOY 6082T651 USING INTERLAYER OF SS304

It is the need of current automotive industries towards economical fabrication with improved mechanical properties of aluminium thin sheets. This paper summarize comparative work on the resistance spot welding of aluminium alloy 6082T651, without interlayer and with interlayer of SS304 having 0.3 mm thickness. Welding current (AMP), electrode force (N) and welding time (Cycle) were studied as input parameters. Range of Electrode Force was 2300 N, 3600 N and 4900 N, Welding Time was 1 cycle, 3 cycles and 5 cycles, Welding Current was 23 KA, 26 KA and 29 KA. Taguchi method is used to generate design matrix for experimental work. Failure load and nugget diameter were output parameters for this work. Effect of interlayer on the failure load is area of interest in this work and how thickness of interlayer will affect the failure load is observed during experiments. It was observed that formation of inter-metallic compounds between aluminium alloy 6082T651 and SS304 significantly affects the failure load of joints