Study of joining mechanism of ABS polymer and steel/aluminum by resistance spot welding

The joining of metal and polymer is an increasingly important method to get lightweight components in the development of manufacturing industry nowadays. In this article, metal and polymer lap joint was achieved by means of resistance spot welding (RSW) and ultrasonic assistance welding (UAW). The joining mechanism of lap joint was analyzed by OM, TEM on microstructure at the interface of lap joints and XPS and IR spectra was discussed based on the following different ones: mechanical-interlocking, diffusion bond and coordination bond. The results showed that it was the combined action that played an important role in the effective joining work. Besides, ultrasonic assistance was used in the study to aid welding process based on its high-frequency ultrasonic vibration, which made joints shaping better and improved tensile strength visibly contrast to joints with the same lower heat input parameters.