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ALTERNATELY DIRECT RESISTANCE SPOT WELDING OF AL-TO-AL, AL-TO-STEEL, AND STEEL-T0-STEEL WITH WELDING ELECTRODE HAVING OXIDE-DISRUPTING STRUCTURAL FEATURES
ALTERNATELY DIRECT RESISTANCE SPOT WELDING OF AL-TO-AL, AL-TO-STEEL, AND STEEL-T0-STEEL WITH WELDING ELECTRODE HAVING OXIDE-DISRUPTING STRUCTURAL FEATURES
A method of resistance spot welding workpiece stack-ups of different combinations of metal workpieces with a single weld gun using the same set of welding electrodes is disclosed. In this method, a set of opposed welding electrodes that include an original shape and oxide-disrupting structural features are used to resistance spot weld at least two of the following types of workpiece stack-ups in a particular sequence: (1) a workpiece stack-up of two or more aluminum workpieces; (2) a workpiece stack-up that includes an aluminum workpiece and an adjacent steel workpiece; and (3) a workpiece stack-up of two or more steel workpieces. The spot welding sequence calls for completing all of the aluminum-to-aluminum spot welds and/or all of the steel-to-steel spot welds last.
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