Influence adding silicon and zinc powders to the spot-welded area of dissimilar metals on the weld nugget mechanical properties

The process of spot welding has been and remains one of the most critical manufacturing processes; the vehicle industry requires frequent use of this process. In several applications, welding dissimilar metals were needed to minimize costs and increase product quality. Due to the different specifications of welded metals, it is necessary to study this situation and improve the welding area’s specifications. In this work, Al 1035 and SAE1006 were welded because of their wide use. Adding two distinct types of metal powders to the welding area helped to enhance the welding zone features and decrease the welding current, providing for a better bond. The influence of welding current and welding duration on the outcome was examined.