Effects of welding parameters and surface pretreatments on resistance spot welding of AZ31B Mg alloy

The resistance spot weldability of AZ31B magnesium alloy using AC (alternating current) was investigated in this paper. The surfaces of sheet coupons were prepared by acetone cleaning (as-received) and some coupons were also cleaned with chromic acid (H2Cr2O7) after acetone cleaning (acid-cleaned). The surfaces of the as-received AZ31B sheets consisted of MgO, Mg(OH)2, and MgCO3. The extent and thickness of the surface oxide/reaction layer of the sheets varied according to the fabrication process of the sheets, and resulted in different contact resistance. Effects of welding current and weld time were investigated while the electrode force was kept constant. The results indicated that the as-received sheets produced expulsion both at the faying surface and at the work piece/electrode interface due to high contact resistance. Diluted chromic acid cleaning reduced contact resistance and produced good weld quality. Increasing the welding current and weld time enhanced not only the nugget size and joint strength, but also increased indentation on the weld surfaces. A weld lobe was established considering the minimum joint strength, weld expulsion, and surface indentation based on a relevant American Welding Society Standard.