Suggestion of an Indicator to Evaluate Material Deposition in Resistance Spot Welding: Weld–Surface Interaction Index

Resistance spot welding (RSW) is still leading joining process in the automotive industry due to the simplicity and speed of the process. On the other hand, galvanized steel sheets provide improvement in corrosion resistance of the auto body. Material deposition has an influence on the corrosion resistance and weld strength; however, in the literature very little effort has been made to identify any weld–surface interaction numerically. In this study, a numerical approach called “Weld–Surface Interaction Index” (I_WSI) has been introduced to investigate the effect of material deposition on the corrosion sensitivity of the welding zone and its periphery. A systematic investigation was carried out to better understand the effects of an electrode cap–galvanized steel sheet interface on the corrosion resistance of spot-welded steel. The chemical composition of DP600 steel sheet and Z-Trode electrode cap was analyzed by using a spectrometer. The specimens were then joined by using same caps up to 1200 welds. SEM–EDS analysis was also performed on the chosen specimens to determine the weight percentages (wt.%) of Fe, Zn and Cu. EDS analysis results and coefficient of variation wt.% of Fe, Zn and Cu were used to compose I_WSI formula. In the proposed formula, wt.% of Zn represented resistivity of the cover to corrosion, while wt.% of Fe represents the vulnerability.