Influence of variable processing conditions on the quasi-static and dynamic behaviors of resistance spot welded aluminum 6061-T6 sheets

The mechanical properties of the weld regions of a 6061-T6 resistance spot welded lap joint are determined. The change in mechanical properties resulting from RSW are linked to the changes observed in the microstructure. Processing currents and strain rates are varied to probe the effects of processing temperature at strain rates from 10−3 to 103 s−1. Results show that material strength decreases within the heat affected zone (HAZ) and fusion zone due to precipitate dispersion. Further, decreased ductility results at quasi-static strain rates from accelerated crack growth arising near voids formed during weld formation, but the short time scale at higher strain rates limits the ability for crack growth from these voids allowing the material to exhibit higher ductility. Overall, significant changes in the mechanical behavior across the weld resulting from a change in microstructure congruent with precipitate dispersion are apparent for all processing conditions.