Caleb Schenck

Resistance spot welding is a critical joining technique in automobile assembly. The load carrying properties of spot welds are generally accepted to correlate with weld diameter, which increases with increasing weld current or duration. The formation of a softened layer, or weld halo, surrounding the fusion zone in a spot-welded third generation (Gen3) advanced high strength steel (AHSS) was recently reported in the literature. To optimize weld performance by schedule design, it is necessary to understand the halo formation characteristics and potential impacts. Accordingly, welding of a Gen3 AHSS was performed using weld times between 130 – 1300 ms. Microhardness mapping characterized weld microhardness and the evolution of the halo during welding. Electron probe microanalysis and timeof-flight secondary ion mass spectrometry enabled measurement of solute distributions through the weld halo, while scanning electron microscopy was used for microstructural characterization. The solidified structure was examined using light-optical microscopy, and with the microhardness and compositional data, used to infer the mechanism by which the halo forms during welding. It was found that the halo develops due to solute rejection from a cellular solidification front that advances towards the center of the fusion zone while weld current is applied. Extended weld times increase the size of the weld halo and the solute content of the inner fusion zone. The decrease in weld halo microhardness and the increase in inner fusion zone microhardness is largely explained by the changes in local carbon content associated with halo formation.