Performance of resistance spot weld caps coated with Ni and Fe aluminide alloys by electro spark deposition on hot dip galvanized steel

Resistance spot welding (RSW) is widely used as a main joining technique in industry and the electrode caps are frequently replaced because of degradation during service. In this study, G type copper RSW were coated with Fe Ni based Fe3Al, FeAl, Ni3Al, NiAl alloys by Electro-Spark Deposition (ESD), providing resistance to hot deformation, oxidation Zn evaporation from sheet metal. The ESD tested in-situ on dip galvanized steel order assess performance caps. For purpose, three different coating voltages selected for each electrode, 12 cap coatings produced total. Fifty welds consecutively manufactured same parameters electrodes. Hardness measurements, macrostructural examination, Ultrasonic Testing (UT) chisel tests performed welded samples produced. addition, effects investigated microstructural development, hardness variations deformation capacity welds. Results showed that cross section thickness values sample made Ni3Al better results than other cross-sectional nuggets was lower all 158 V aluminide can be listed best worst NiAl, FeAl.