Effect of governing metal thickness and stack orientation on weld quality and mechanical behaviour of resistance spot welding of AA5754 aluminium

► Results from over 1000 mechanical test samples are presented and discussed. ► The GMT has a controlling effect on the weld diameter that can be achieved. ► The GMT dominates the strength attainable in the three joint geometries tested. ► No effect on weld quality and strength was found due to asymmetry of MFDC welding.