Research on the Effect of Electrode Erosion on Spot Welding Nucleation of Heterogeneous Aluminum Alloys with Different Thickness

HAN Lei; PENG Jiangtao; SONG Jianling; YANG Jupeng

doi:10.7512/j.issn.1001-2303.2026.06.11

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Research on the Effect of Electrode Erosion on Spot Welding Nucleation of Heterogeneous Aluminum Alloys with Different Thickness
Vol. 56, Issue 6, Pages: 84-91(2026)
Received：01 September 2025，

Revised：2025-10-17，

Published：20 June 2026
DOI： 10.7512/j.issn.1001-2303.2026.06.11
稿件说明：

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韩磊，彭江涛，宋建岭，等.电极表面侵蚀对不等厚异种铝合金点焊形核的影响研究［J］.电焊机，2026，56（6）：84-91. DOI： 10.7512/j.issn.1001-2303.2026.06.11.

HAN Lei, PENG Jiangtao, SONG Jianling, et al.Research on the Effect of Electrode Erosion on Spot Welding Nucleation of Heterogeneous Aluminum Alloys with Different Thickness[J].Electric Welding Machine, 2026, 56(6): 84-91. DOI： 10.7512/j.issn.1001-2303.2026.06.11.

摘要

针对CZ-7型号新一代运载火箭贮箱5 mm厚2219铝合金与2 mm厚5A06铝合金不等厚异种铝合金点焊中连续焊接后出现的脱焊问题，研究了电极表面侵蚀状态对点焊形核的影响。通过工艺试验排除了设备功率输出不稳定和冷却效果不佳、点焊工艺参数不适合等外部因素，在连续多次点焊后电极表面发生侵蚀状态下，电极端面直径变大，由原球面变为平台面，电极与产品间的接触面积变大，焊接电流密度降低，产热变小；电极表面侵蚀越严重，铜铝化合物含量越多，导电性变差。焊接电流密度降低和导电性变差容易造成形核不充分或无法形核，导致试件焊点直径过小或无核。有限元仿真分析结果证明了电极侵蚀后端面弧度严重变形，会导致熔核区域电流密度明显下降，产热不足，无法形核。将呈平面状的电极工作端面修磨成球面，再次进行点焊试验，防晃框焊点无脱焊质量问题，满足点焊质量要求，通过修磨故障电极后点焊成核试验验证了电极侵蚀下点焊成核分析的正确性。

Abstract

This paper made research on spot welding nucleation of 5mm thick 2219 aluminum alloy and 2mm thick 5A06 aluminum alloy under electrode erosion in the case of multiple consecutive spot weld. And this spot welding process is commonly used for the Long March 7. Finite element simulation and process experiments were conducted to analyze the effect of electrode erosion on spot welding nucleation of heterogeneous aluminum alloys with different thickness. After excluding external factors such as unstable power output of the equipment

poor cooling effect of the equipment

and inappropriate spot welding process parameters

the analysis results indicate that the diameter of the electrode end face increases because of electrode erosion

and the contact area between the electrode and the specimen increases

this leads to the welding current density decreases and heat generation reduces. And The result is that the more severe the wear on the electrode surface

the higher the content of copper aluminum compounds

and the poorer the conductivity. After the surface condition of the electrode deteriorates

the electrode end face forms copper aluminum compounds

and the conductivity decreases

these can easily lead to insufficient or impossible nucleation during the spot welding process. The finite element simulation analysis results indicate that severe deformation of the end face curvature after electrode erosion can lead to a significant decrease in current density in the fusion zone. This causes insufficient heat generation

and inability to nucleate. The spot welding tests were conducted again after the working end face of the flat electrode was ground into a spherical surface. The test welding points had no quality problems of detachment. The correctness of spot welding nucleation analysis under electrode erosion was verified through spot welding nucleation tests after grinding the faulty electrode.

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