PSI - Issue 77

7

Andreas Fezer et al. / Procedia Structural Integrity 77 (2026) 229–236 Andreas Fezer / Structural Integrity Procedia 00 (2026) 000–000

235

Mean values

0 1 2 3 4 5 6 7 8 9 10

Spot diameter [mm]

30 kA

35 kA

40 kA

45 kA

s = 1 mm s = 2 mm s = 3 mm

Figure 6. Influence of the sheet thickness on spot diameter

4. Conclusions This article investigated the influence of various parameters on spot diameter during resistance spot welding (RSW). The experiments were conducted using the aluminum alloy EN AW-6014. The welding current, electrode force, adhesive application, and sheet thickness were varied. The following observations were made: • Spot diameter increases with increasing welding current • Spot diameter decreases with increasing electrode force • Welding with adhesive leads to larger spot diameters • Spot diameter is larger for a sheet thickness of 2 mm than for 1 mm; but at 3 mm the spot diameter decreases slightly again The observed patterns made here will be mostly similar for other aluminum alloys. However, it should be noted that the welding parameters to be set for other aluminum alloys may differ from those used here. In the future, we plan to try this study with a different alloy. Furthermore, we also aim to use AI methods with larger data sets in order to be able to transfer observed patterns to other alloys in the future.