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Meeting

2026 TMS Annual Meeting & Exhibition

Symposium

Late News Poster Session

Presentation Title

J-18: Microstructural and Mechanical Characterization of Resistance Spot-Welded Aluminum Sheet/Casting Joints

Author(s)

Jae Hun Kim, Changwook Ji, Jooyong Cheon

On-Site Speaker (Planned)

Jae Hun Kim

Abstract Scope

Lightweight vehicle design has become essential due to stricter environmental regulations and fuel efficiency demands. Aluminum materials are increasingly applied in automotive body and chassis components, where sheet and casting combinations offer both structural performance and weight reduction. However, resistance spot welding of dissimilar aluminum materials poses challenges due to differences in thermal and electrical conductivities, causing uneven nugget growth and localized defects. In this study, aluminum sheet/casting joints were fabricated by resistance spot welding, and their fusion zone morphology and solidification characteristics were analyzed metallographically. Mechanical performance was evaluated through tensile-shear testing and hardness distribution measurements. Fracture modes and crack propagation were also examined to reveal correlations between microstructure and mechanical behavior. The results provide fundamental insights for improving weld reliability and optimizing joining processes for lightweight aluminum automotive structures.

Proceedings Inclusion?

Undecided

Keywords

Aluminum, Joining, Mechanical Properties

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