Electrode wear investigation of aluminium spot welding by motion overlay

Research output: Contribution to journalResearch articleContributedpeer-review


The amount of aluminium sheets in future body-in-white concepts is still on the rise. There is a need for optimizing the joining techniques, caused by the different characteristics compared to the established steel components. Especially the electrode life for resistance spot welding as a reliable and established process needs to be improved. One reason for the short electrode life when welding aluminium is the insulating effect of the aluminium oxide layer. One possibility to reduce the electrode wear is the mechanical destruction of the oxide layer before the welding. This paper describes the influence of a translational and rotational electrode movement on the electrode wear. The oxide layer destruction is detected by resistance measurement. It could be shown that the destruction of the oxide layer already occurs at low movements. However, a homogeneous, large-area destruction is necessary for a wear reduction.


Original languageEnglish
Pages (from-to)749-760
Number of pages12
JournalThe International Journal of Advanced Manufacturing Technology
Issue number3-4
Publication statusPublished - Nov 2022

External IDs

Scopus 85139176284
Mendeley daa237c1-a8b3-3f97-8758-bd8b94039869
unpaywall 10.1007/s00170-022-10157-8
ORCID /0000-0003-0763-552X/work/142251868



  • Aluminium alloys, Electrode wear, Oxide layer, Resistance spot welding