Abstract: A multi-tiered weld program that is effective in resistance spot welding of dissimilar materials is disclosed. The process is repeatable across a multitude of grades/thicknesses, and number of sheets of conductive materials, and is possible to perform with traditional weld tooling and electrodes. Different size/different material/different contact face geometries weld surfaces are used to balance thermal properties of the materials, and the process is designed to create a small, consistent Intermetallic Compound (IMC) that is effective in holding two different conductive materials together with a high level of strength that is suitable for industrial mass production. The multi-tiered resistance spot weld process uniformly preheats, welds, and cools the samples to control the formation of the IMC that is formed therein.

Abstract: A multi-tiered weld program that is effective in resistance spot welding of dissimilar materials is disclosed. The process is repeatable across a multitude of grades/thicknesses, and number of sheets of conductive materials, and is possible to perform with traditional weld tooling and electrodes. Different size/different material/different contact face geometries weld surfaces are used to balance thermal properties of the materials, and the process is designed to create a small, consistent Intermetallic Compound (IMC) that is effective in holding two different conductive materials together with a high level of strength that is suitable for industrial mass production. The multi-tiered resistance spot weld process preheats, welds, and cools the samples to control the formation of the IMC that is formed therein.