| Title |
Effect of the Interlocked Element Structure on REW Joining Properties of Aluminum Sheets/Steel Sheets |
| Authors |
오욱진(Wook Jin Oh) ; 류현정(Hyeon Jung Ryu) ; 이창욱(Chang Wook Lee) ; 유지홍(Ji Hong Yoo) ; 김민수(Min Soo Kim) ; 이춘수(Choon Soo Lee) |
| DOI |
https://doi.org/10.3365/KJMM.2025.63.11.873 |
| ISSN |
1738-8228(ISSN), 2288-8241(eISSN) |
| Keywords |
Aluminum sheet; Resistance Element Welding; Interlock; Mechanical properties; Welding properties |
| Abstract |
The automotive industry's ecosystem is rapidly shifting from internal combustion engine (ICE)
vehicles to electric vehicles (EVs). This transition significantly increases vehicle weight due to added batteries
and numerous convenience features. As a result, the use of aluminum in vehicles is rising. However, joining
dissimilar materials like aluminum and steel remains a challenge because of their different mechanical and
thermal properties. Resistance Element Welding (REW) is widely used for joining dissimilar materials such
as aluminum and steel, due to its strong bonding capability and compatibility with existing equipment. This
hybrid technique combines mechanical pressing with the thermal properties of resistance spot welding.
However, when applied to aluminum sheets, the joint quality often deteriorates compared to die-cast or
extruded aluminum. This study analyzes how the element's interlocked structure affects the joining behavior
of aluminum sheets. The developed REW process produced a robust interlock, significantly improving both
push-out force and bonding strength. Interestingly, although weld nugget size decreased with distance from
the element’s center, bonding strength increased, likely due to element deformation and intermetallic
compound formation. Ultimately, the robustly formed interlock also ensured watertightness performance. |