Unprecedented Welding Close to Sheet Edges of Aluminum Alloys

Common Issues with Aluminum Alloy Edge Spot Welds

How close to the edge of aluminum alloys can I weld?

  1. Resistance spot welding close to aluminum alloy sheet edges within 10mm is not considered possible
    • The sheet edges are deformed and become very non-cosmetic
    • There is much electrode indentation and reduction of thickness at the weld
    • There is also much expulsion of weld metal at the weld interface through the sheet edges
    • Weld electrodes pick up some molten aluminum and electrode life is not satisfactory
    • Weld quality is also often questionable
  2. Edge joints are usually riveted (heavier and more expensive part) or laser welded (more expensive process)
  1. IWSL’s new FMRW spot welds close to the aluminum alloy sheet edges are very cosmetic
    • No loss of thickness at the weld
    • No bulging at the sheet edge
    • Non-melted outer layers of the weld nuggets help maintain long electrode life in excess of 1000 welds between dressing operations
    • No expulsion of weld metal at the weld interfaces for welds up to 3 mm from the edge
    • Weld to weld distances closer than normally permitted and weld sizes larger than normally possible can be chosen by the designer without regard to the sheet thicknesses welded.
3.5mm Aluminum Edge Weld



3.5mm aluminum edge weld, front view Two sides of FMRW spot welds in Aluminum alloy 6061-T6 show cosmetic welds at a distance of 3.5mm from the sheet edge. Weld Section Macrographs in the next cross-section slide demonstrate excellent weld quality.

Aluminum edge spot welding cross section for quality

(Etched in Na0H Solution)
FMRW spot weld in Aluminum alloy 6061-T6 at a distance of 3.5 millimeters from the sheet edge. Weld Section Macrograph demonstrates excellent weld quality. Weld size is satisfactory for the sheet thickness. Non-melted outer surfaces promote good electrode life in excess of 1000 welds between electrode dressing operations.

4.5mm aluminum edge weld


4.5mm aluminum edge weld, front side Two sides of FMRW spot welds in Aluminum alloy 6061-T6 show cosmetic welds at a distance of 4.5 millimeters from the sheet edge.

2.5mm aluminum edge weld


2.5mm aluminum edge weld - front view Two sides of FMRW spot welds in Aluminum alloy 6061-T6 show cosmetic welds at a distance of 2.5 millimeters from the sheet edge. Welds are of high quality and cosmetic. There is slight expulsion of weld metal at the weld interface at this distance from the edges.

How can the FMRW Welding Solutions help you?

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