Influence of the electrode geometry on the microstructure in copper braid assemblies during resistance spot welding

This article presents the effects of welding electrode geometries during resistance spot welding. The optimized electrode geometry creates best results for welding copper braids into copper alloy substrates by reducing defects generated on the joints. The new electrode geometry can benefit multiple applications, where lower energy is needed to join the parts. A mechanical cycling test was conducted to validate the welding joint produced by the new electrode geometry. The microstructure of the joint showed that the new electrode geometry improves mechanical properties of the weld by changing the distribution of the heat affected zone and by consequence, the new electrode geometry changes the hardness of the weld zone and in turn results in less fragile weld joint.