Effect of welding fixture on distortion control and tensile strength of AA5182 resistance spot welds

Abstract This study presents a comprehensive investigation into the effects of fixtures on distortion control, tensile strength, and crack formation in the heat-affected zone (HAZ) during resistance spot welding (RSW) of aluminum alloy AA5182. Tensile-shear results indicate that interfacial fracture is the primary failure mode, while clamping substantially reduces expulsion, enhances joint quality, and nearly eliminates HAZ cracking. The finite element method (FEM) simulation was used to analyze mechanical strength, heat generation, and stress distribution across welded specimens. Moreover, microstructural characterization confirms that cracks mechanism in the HAZ are linked to the grain segregation and make chance for low-melting eutectic to backfill the intergranular cracks. The microstructure variation across weld zone plays a crucial role in determining the mechanical performance of the weld, including strength, ductility, and resistance to cracking. These findings emphasize the pivotal role of fixture on enhancing weld quality and offering a robust framework for optimizing RSW aluminum alloys.