Abstract: Disclosed are welds formed from improved resistance spot welding, as well as methods of improved resistance spot welding. Resistance spot welding includes positioning a magnet carrier having a plurality of electromagnets on at least one electrode of two electrodes. The method includes positioning a first metal sheet and a second metal sheet between the two electrodes where at least one of the first metal sheet or the second metal sheet includes an aluminum alloy. The method includes positioning the forming a weld nugget by applying a magnetic field from the plurality of electromagnets through the weld while applying a current through the electrodes to stir a portion of the first metal sheet and the second metal sheet forming a weld nugget and adjusting the magnetic field to control at least one characteristic of the weld nugget. Forming the weld nugget joins the first metal sheet with the second metal sheet.

Abstract: Disclosed are welds formed from improved resistance spot welding. Resistance spot welding includes positioning a first metal sheet and a second metal sheet between two electrodes, contacting the two electrodes together on to opposing surfaces of the first metal sheet and the second metal sheet, and applying at least a minimum current to the first metal sheet and the second metal sheet through the two electrodes to form a weld having a minimum weld size to join the first metal sheet with the second metal sheet. At least one of the first metal sheet and the second metal sheet is a fusion alloy where the composition of at least one outer layer of the sheet is different from the composition of the core of the sheet.

Abstract: Welding techniques, including, for example, resistance spot welding, can be used to join or weld two or more metal sheets together. A clamping force and an electric current can be applied to two or more sheets to create localized melting that combines the material of the two sheets. Applying a clamping force and a cooling current can include gradually decreasing the amount of the electric current applied to the weld while applying the forging force. By adjusting the amount of the electric current applied to the weld can allow the weld to cool gradually, which may reduce thermal stresses and allow the forging force to close cracks, pores, or otherwise be used to remove or prevent defects formed in the weld.