Geometrical degradation of electrode and liquid metal embrittlement cracking in resistance spot welding

Electrode degradation during the resistance spot welding (RSW) of coated steels has been a major challenge in automobile manufacturing as it affects the weld quality in terms of nugget size, defects, and mechanical properties. In this work, we investigate the effect of electrode degradation on such a defect, Zn-assisted liquid metal embrittlement (LME) cracking, in RSW by producing 400 consecutive welds of galvannealed TRIP steel. Infrared thermography, carbon imprinting, dynamic resistance, optical imaging, SEM, and EDS were used to characterize various phenomena during consecutive welding. LME crack severity was found to be unaffected in the first 80 consecutive welds. However, the severity declined sharply between 80-200 welds, and further, it remained low in 200-400 welds. The electrode experienced geometrical degradation (increase in the radius of curvature and face diameter) and metallurgical degradation (Cu-Zn-Fe alloy layer formation) during consecutive welding. The geometrical degradation, specifically the radius of curvature, was confirmed as the main factor affecting LME cracking. On the other hand, metallurgical degradation did not affect the LME cracking in the first 200 welds as its influence was overcome by the geometrical degradation. However, a small impact of metallurgical degradation was detected in 200-400 welds in the form of local rise and fall in the temperature and LME crack length.