Improvement of aluminium alloy and polymer single sided coaxial resistance spot welded joint with steel cover plate

Improvement of aluminium alloy and polymer single sided coaxial resistance spot welded joint with steel cover plate | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Improvement of aluminium alloy and polymer single sided coaxial resistance spot welded joint with steel cover plate Chao Ding, Xiaoge Kang, Na Wu, Jun Xiao, Shengnan Gai, Shujun Chen This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6011172/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract A reusable steel cover plate was introduced into the aluminium alloy/nylon dissimilar materials single sided coaxial resistance spot welding process, to address the alloying between the electrode welding surface and aluminium alloy workpiece, which limited the continuous increase in heat input, thus further limited the serviceability of the welded joint. Three-dimensional numerical simulations were employed to investigate the variations in current conduction, heat generation and heat distribution during the welding processes with and without the introduction of the steel cover plate. With the introduction of the steel cover plate, the main heat production area changed from the copper electrode/aluminium alloy workpiece interface to the steel cover plate and the copper electrode/steel cover plate interface, and the temperature distribution on the aluminium alloy workpiece presented a more uniform state. Nylon melted and spread more on the aluminium alloy surface, thus accordingly, the average peak tensile shear load was expanded from 2.6 kN to 4.1 kN, with an enhancement of 57.7% at a welding current of 7.5 kA. Resistance spot welding Aluminium alloy-nylon Dissimilar materials Numerical simulation Mechanical property Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 05 May, 2025 Reviewers invited by journal 18 Apr, 2025 Editor invited by journal 17 Feb, 2025 Editor assigned by journal 14 Feb, 2025 First submitted to journal 12 Feb, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6011172","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":444721043,"identity":"5e8a6519-247c-46ea-ab7a-c287c6d39224","order_by":0,"name":"Chao Ding","email":"","orcid":"","institution":"Beijing University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Chao","middleName":"","lastName":"Ding","suffix":""},{"id":444721044,"identity":"add72026-fcbb-4650-b58b-7f883038ffca","order_by":1,"name":"Xiaoge Kang","email":"","orcid":"","institution":"Beijing University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Xiaoge","middleName":"","lastName":"Kang","suffix":""},{"id":444721045,"identity":"0753a48c-a560-4187-a41f-ea039418817d","order_by":2,"name":"Na Wu","email":"","orcid":"","institution":"Beijing University of Civil Engineering and Architecture","correspondingAuthor":false,"prefix":"","firstName":"Na","middleName":"","lastName":"Wu","suffix":""},{"id":444721046,"identity":"fade65f5-85fd-404f-9516-f4f3d4160837","order_by":3,"name":"Jun Xiao","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA3UlEQVRIiWNgGAWjYBACxgYQacDAwC/BkIAQIEqL5AyglgPEaIEDgxtAgigtzDNyDzDzFNjJGd9ueCb9gcFGdsMB5mcP8DpsRl4C4wyDZGOzOwfSJA4wpBlvOMBmboBfS44BwwcD5sRtNxJAWg4nbjjAwyZBUEuCQX3i5hlgLf+J1PLBAGi4BFjLASK09LwxODjD4LixxJ0DyRZngJ6aeZjNDK8Ww/Ycw8c8f6rl+Gf3JN6oqLCT7Tve/Ay/lgZwbIAATwI4ThmY8akHAnkEk/0AAbWjYBSMglEwUgEAHhJJ5+ahfGQAAAAASUVORK5CYII=","orcid":"https://orcid.org/0000-0002-2782-2739","institution":"Beijing University of Technology","correspondingAuthor":true,"prefix":"","firstName":"Jun","middleName":"","lastName":"Xiao","suffix":""},{"id":444721047,"identity":"97763e25-8be4-4123-b30c-bc61669959c0","order_by":4,"name":"Shengnan Gai","email":"","orcid":"","institution":"Beijing University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Shengnan","middleName":"","lastName":"Gai","suffix":""},{"id":444721048,"identity":"e378da72-883a-4d0d-98e4-2c18bcd131eb","order_by":5,"name":"Shujun Chen","email":"","orcid":"","institution":"Beijing University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Shujun","middleName":"","lastName":"Chen","suffix":""}],"badges":[],"createdAt":"2025-02-12 02:47:13","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6011172/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6011172/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":81401524,"identity":"5b0a8e5c-3435-4e23-8804-a57e8ccf386f","added_by":"auto","created_at":"2025-04-25 16:46:26","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1110132,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6011172/v1_covered_b078bf69-8dfe-4b2b-a483-d49a2a7e5160.pdf"}],"financialInterests":"","formattedTitle":"Improvement of aluminium alloy and polymer single sided coaxial resistance spot welded joint with steel cover plate","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Resistance spot welding, Aluminium alloy-nylon, Dissimilar materials, Numerical simulation, Mechanical property","lastPublishedDoi":"10.21203/rs.3.rs-6011172/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6011172/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eA reusable steel cover plate was introduced into the aluminium alloy/nylon dissimilar materials single sided coaxial resistance spot welding process, to address the alloying between the electrode welding surface and aluminium alloy workpiece, which limited the continuous increase in heat input, thus further limited the serviceability of the welded joint. Three-dimensional numerical simulations were employed to investigate the variations in current conduction, heat generation and heat distribution during the welding processes with and without the introduction of the steel cover plate. With the introduction of the steel cover plate, the main heat production area changed from the copper electrode/aluminium alloy workpiece interface to the steel cover plate and the copper electrode/steel cover plate interface, and the temperature distribution on the aluminium alloy workpiece presented a more uniform state. Nylon melted and spread more on the aluminium alloy surface, thus accordingly, the average peak tensile shear load was expanded from 2.6 kN to 4.1 kN, with an enhancement of 57.7% at a welding current of 7.5 kA.\u003c/p\u003e","manuscriptTitle":"Improvement of aluminium alloy and polymer single sided coaxial resistance spot welded joint with steel cover plate","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-04-25 16:38:08","doi":"10.21203/rs.3.rs-6011172/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-05-05T09:03:53+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-04-18T07:35:45+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"Welding in the World","date":"2025-02-17T06:26:47+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-02-14T14:54:02+00:00","index":"","fulltext":""},{"type":"submitted","content":"Welding in the World","date":"2025-02-12T20:29:10+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"7d5f09c9-efc7-4b77-83d5-987aa207be6d","owner":[],"postedDate":"April 25th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2025-08-21T15:29:42+00:00","versionOfRecord":[],"versionCreatedAt":"2025-04-25 16:38:08","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-6011172","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6011172","identity":"rs-6011172","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}