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<p>This study investigates the microstructure and mechanical properties of dissimilar metal joints between 6061 aluminum alloy and TC4 titanium alloy, fabricated using resistance spot welding with process tape process. The influence of welding parameters, such as welding current, welding time, and electrode pressure, on the weld joint’s morphology, nugget size, and fracture mode is systematically analyzed. The results show that the Al/Ti spot weld joints exhibit a typical fusion-brazing characteristic, with TiAl<sub>3</sub> and Ti<sub>2</sub>Al<sub>5</sub> intermetallic compounds formed at the interface. Two fracture modes were observed: button fracture and interfacial fracture. The tensile shear force first increases and then decreases with increasing welding parameters, reaching a maximum of 7.02&#xa0;kN. This study provides a theoretical foundation and technical support for the welding of thin-walled Al/Ti dissimilar metal structures.</p>

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Microstructure and Mechanical Properties of Al/Ti Dissimilar Welded Joints Fabricated by Resistance Spot Welding with Process Tapes

  • 期刊论文

  • 发表日期：

    2026年4月1日

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  • Haohan Zhang,
  • Yinyin Pei,
  • Yuanxun Shen,
  • Xiaoxue Ren,
  • Tuanjie Han,
  • Xinge Zhang,
  • Wenquan Wang

摘要

This study investigates the microstructure and mechanical properties of dissimilar metal joints between 6061 aluminum alloy and TC4 titanium alloy, fabricated using resistance spot welding with process tape process. The influence of welding parameters, such as welding current, welding time, and electrode pressure, on the weld joint’s morphology, nugget size, and fracture mode is systematically analyzed. The results show that the Al/Ti spot weld joints exhibit a typical fusion-brazing characteristic, with TiAl3 and Ti2Al5 intermetallic compounds formed at the interface. Two fracture modes were observed: button fracture and interfacial fracture. The tensile shear force first increases and then decreases with increasing welding parameters, reaching a maximum of 7.02 kN. This study provides a theoretical foundation and technical support for the welding of thin-walled Al/Ti dissimilar metal structures.