OBRABOTKAMETALLOV technology Vol. 27 No. 3 2025 Fig. 1. Dimensions of the lap joint specimen produced by resistance spot welding (RSW) for tensile testing Fig. 2. Process scheme and cycle diagram of resistance spot welding (RSW) For resistance spot welding (RSW) of 2.5 mm thick aluminum alloys, three variable parameters were used: welding current (ranging from 5 to 30 kA), welding period (from 1 to 5 seconds), and electrode force (from 2,000 to 5,000 N). The experiment consisted of thirteen series, each including welding of five samples: four for static shear tensile testing and one for metallographic analysis and hardness measurement. Samples for metallographic analysis and hardness testing were cut perpendicular to the longitudinal direction of the welded specimens from the central region of the joint. Preparation of metallographic specimens involved cutting samples into 12 × 12 mm blanks, grinding, polishing, and etching to reveal the microstructure. Microstructure examination was performed using an optical microscope Mikromed 2. Hardness measurements were carried out in two directions (along the nugget radius and through the sheet thickness) using a microhardness tester with a 100 g load.
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