X. ZHU et al.: MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED ...
451–457
MICROSTRUCTURE AND PROPERTIES OF 6082/7075
MAGNETIC-FIELD-ASSISTED RESISTANCE-SPOT-WELDED
JOINTS
MIKROSTRUKTURA IN LASTNOSTI Z MAGNETNIM POLJEM
PODPRTEGA UPOROVNEGA TO^KOVNO ZV ARJENEGA SPOJA
MED Al ZLITINAMA VRSTE 6082 IN 7075
Xiaoou Zhu
*
, Zhanqi Liu, Guili Yin, Yu Li
School of Materials Science and Engineering, Liaoning University of Technology, Jinzhou, Liaoning, People’s Republic of China
Prejem rokopisa – received: 2024-03-31; sprejem za objavo – accepted for publication: 2024-05-09
doi:10.17222/mit.2024.1144
To advance automotive lightweighting, a study was conducted on steady-state magnetic-field-assisted resistance spot welding of
6082 aluminum alloy (1.0 mm thick) and 7075 aluminum alloy (1.5 mm thick) with thermal compensation. The influence of
varying magnetic induction intensity on the microstructure and tensile properties of welded joints was assessed under the same
welding current, time and electrode pressure. The results revealed that the Lorentz force induced by magnetic induction inten-
sity ranging from 0 mT to 60 mT could promote an outward circumferential movement of molten metal within the weld nugget.
This movement, at the same time, led to an increase in the weld-nugget size and improved the efficiency of thermal resistance.
At a magnetic induction intensity of 80 mT, no weld-nugget formation occurred in the welded joint. Microstructural observa-
tions at magnetic induction intensities of 0 mT and 60 mT revealed equiaxed grains at the nugget center and columnar dendrite
grains at the nugget edge in the welded joints. The Lorentz force accelerated the weld cooling rates after the addition of mag-
netic field, refining the weld grain structure. Tensile properties of the welded joints gradually improved with increasing the mag-
netic induction intensity from 0 mT to 60 mT, driven by the weld nugget size expansion and weld grain refinement. Overall, the
present study indicated that the magnetic induction intensity of 60 mT resulted in the most favorable comprehensive mechanical
properties of the investigated welded joints.
Keywords: aluminum alloys, thermal compensation, magnetic-field-assisted resistance spot welding, properties
Avtorji so, z namenom zmanj{anja mase naprednih avtomobilskih karoserij, {tudirali uporovno to~kovno varjenje med
plo~evinama iz dveh razli~nih Al zlitin. Varjenje je bilo podprto s stalnim stati~nim magnetnim poljem in termi~no
kompenzacijo. Plo~evina iz Al zlitine tipa 6082 je bila debela 1,0 mm in debelina Al plo~evine iz Al zlitine 7075 je bila 1,5 mm.
Avtorji so ocenjevali spremembo mikrostrukture in mehanskih lastnosti to~kovnih zvarov glede na izbrano gostoto (indukcijo)
magnetnega polja. Razli~no mikrostrukturo in natezno trdnost to~kovnih zvarov so dosegli pri konstantnem elektri~nem toku,
~asu varjenja in tlaku med elektrodama. Rezultati preizkusov so pokazali, da Lorentzova sila povzro~ena z magnetno indukcijo
jakosti od 0 do 60 mT lahko pospe{i zunanje (periferno) kro`no gibanje raztaljene kovine znotraj to~kovnega zvara. Isto~asno to
gibanje pove~a velikost pretalitve in izbolj{a u~inkovitost toplotnega upora. Pri uporabi intenzitete magnetne indukcije 80 mT
avtorji niso opazili nastanka pretalitve (angl.: weld nugget formation) v to~kovnih zvarih. Metalografske preiskave zvarov pri
intenzitetah magnetne indukcije med 0 in 60 mT so v vseh primerih pokazale nastanek enakoosnih kristalnih zrn v sredini
pretalitve in dendritna kristalna zrna na njenih robovih. Lorentzove sile, vzbujene z magnetno indukcijo, so pospe{ile hitrost
ohlajanja in udrobljenje (zmanj{anje velikosti) kristalnih zrn v mikrostrukturi to~kovnih zvarov. Natezna trdnost to~kovnih
zvarov je postopoma nara{~ala z nara{~ajo~o intenziteto magnetne indukcije od 0 do 60 mT pospe{ena z velikostjo pretalitve in
zmanj{evanjem velikosti kristalnih zrn v mikrostrukturi. V celoti je izvedena {tudija pokazala, da so avtorji najbolj{e mehanske
lastnosti to~kovnih zvarov med izbranima plo~evinama iz Al zlitin dosegli pri intenziteti magnetne indukcije 60 mT.
Klju~ne besede: zlitine na osnovi aluminija, termi~na kompenzacija, z magnetnim poljem podprto uporovno to~kovno varjenje,
mirostruktura in mehanske lastnosti
1 INTRODUCTION
Lightweight automobiles represent an effective strat-
egy in addressing global energy and environmental chal-
lenges. A key direction in automotive lightweighting is
the adoption of lightweight materials instead of
high-strength steel, with aluminum’s density being ap-
proximately one-third of that of steel. By completely re-
placing steel with an aluminum alloy, the total weight of
parts in a whole vehicle can be greatly reduced, making
automotive lightweighting feasible.
1
In automotive manufacturing, resistance spot welding
(RSW) technology is a widely employed method for
joining components, offering advantages such as high ef-
ficiency, low cost, and high reliability.
2
However, when
compared to high-strength steel, welding of aluminum
alloys present challenges due to their lower resistivity,
higher thermal conductivity, and larger linear expansion
coefficient. According to literature data,
3,4
RSW technol-
ogy utilizing short welding times, high welding currents,
and elevated electrode pressures can create a substantial
temperature gradient. This gradient, in turn, causes rapid
heating and cooling during welding. Such thermal cycle
Materiali in tehnologije / Materials and technology 58 (2024) 4, 451–457 451
UDK 661.862:621.791.763 ISSN 1580-2949
Original scientific article/Izvirni znanstveni ~lanek MTAEC9, 58(4)451(2024)
*Corresponding author's e-mail:
clzxo@lnut.edu.cn (Xiaoou Zhu)

increases the likelihood of welding defects like shrinkage
cavities and hot cracks in aluminum-alloy RSW joints.
Overcoming these challenges while ensuring the
quality of welded joints has been a longstanding goal for
automotive manufacturers. Traditional methods for en-
hancing the aluminum-alloy RSW-joint quality involve
optimizing the welding parameters, i.e., increasing the
welding time, current, and electrode pressure.
5–7
How-
ever, these methods come with drawbacks like increased
power consumption, reduced welding efficiency, and
electrode wear, which hamper the development of auto-
motive lightweighting and aluminum-alloy RSW tech-
nology.
In recent decades, electromagnetic-assisted technol-
ogy has shown promise in various processes, including
casting,
8,9
arc welding,
10,11
and laser welding.
12,13
Despite
the absence of an apparent arc or molten pool in RSW,
magnetic field plays an important role due to the welding
current generated during RSW. Since 2011, researchers
have applied magnetic-field-assisted technology to RSW,
manipulating the heat-transfer behavior by introducing
permanent magnets, resulting in the development of
magnetic-assisted resistance spot welding
(MA-RSW).
14–16
Currently, MA-RSW technology has
found applications in high-strength steel,
17
stainless
steel,
18,19
and aluminum alloys.
20,21
Recent research has
demonstrated that MA-RSW can effectively increase the
weld-nugget diameter, refine the weld microstructure,
eliminate internal defects, and improve mechanical prop-
erties of welded joints without increasing the welding
heat input.
The 6082 aluminum alloy is known for its heat-treat-
able characteristics, providing medium strength, good
weldability, and corrosion resistance. It is widely used in
the automotive industry, marine engineering, and other
fields.
22,23
Similarly, the 7075 aluminum alloy, also
heat-treatable, offers high strength, good weldability, and
corrosion resistance, making it suitable for applications
in automotive manufacturing.
24
Given the distinct proper-
ties and applications of these alloys, there is a potential
demand for their joining. However, there are limited
analyses of the microstructure and mechanical properties
of dissimilar metal RSW joints obtained using these ma-
terials. Furthermore, little research has been done on
how the microstructure and mechanical properties of
these welded joints change with an enhancement of the
magnetic field.
The present study focused on conducting research on
the 6082 and 7075 aluminum alloys by applying a
steady-state magnetic field during an RSW test of these
different aluminum alloys. The goal was to investigate
how the steady-state magnetic field affects the macro-
morphology, microstructure, and tensile properties of
6082/7075 RSW joints. Additionally, the present study
aimed to optimize the welding process parameters of alu-
minum alloy MA-RSW. This research effort not only has
the potential to contribute to the advancement of light-
weight automotive solutions but also broadens the appli-
cation scope of MA-RSW technology. Furthermore, the
findings of the present study may provide technical sup-
port for the theoretical analysis of high-quality alumi-
num alloy RSW technology.
2 EXPERIMENTAL PART
The materials used in the present study were 6082
and 7075 aluminum alloys, which were supplied in the
T6 condition. Samples in the form of plates had dimen-
sions of (80 × 20 × 1) mm (6082 alloy samples) and (80
× 20 × 1.5) mm (7075 alloy samples). Their chemical
compositions and mechanical properties are presented in
Tables 1 and 2, respectively.
Table 1: Maximal element concentrations of 6082 and 7075 (w/%)
Cu Mg Zn Mn Cr Fe Si Ti Al
7075 1.8 2.6 5.99 0.3 0.21 0.4 0.36 0.22 Bal.
6082 0.1 1.1 0.2 0.95 0.25 0.5 1.3 0.1 Bal.
Table 2: Mechanical properties of 7075 and 6082 aluminum alloys
Yield strength
(MPa)
Tensile strength
(MPa)
7075 501 572
6082 260 310
Prior to RSW, plate samples were arranged to par-
tially overlap one another along the horizontal direction,
creating an overlap area of (20 × 20) mm. The top over-
lapping plate was the 6082 sample, while the bottom
plate was the 7075 sample. Generally, due to the high
electrical and thermal conductivity of aluminum alloys,
the thermal efficiency of resistance heating is not high
during RSW. In addition, the heat distribution is not con-
centrated and it dissipates quickly. To address this issue,
1 mm thick 304 austenitic stainless steel was utilized to
pad the bottom of the 7075 sample for thermal compen-
sation, as detailed in a reference.
25
This approach aimed
to achieve sufficient heat retention to elevate the maxi-
mum temperature, reduce the heat dissipation during
welding, and ultimately facilitate the formation of a
larger weld nugget, as depicted in Figure 1. The spot
X. ZHU et al.: MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED ...
452 Materiali in tehnologije / Materials and technology 58 (2024) 4, 451–457
Figure 1: RSW with thermal compensation

welding was conducted at the center of the overlap area
using a Panasonic single-phase YR-350S AC resistance
welder. The electrode material employed was Cr-Zr-Cu,
with the diameter of the electrode end face measuring
5 mm.
To investigate the influence of a magnetic field on the
microstructure and tensile properties of RSW joints, an
MA-RSW test was conducted. Following the above-men-
tioned welding preparation, eight NdFeB strong perma-
nent magnets were horizontally aligned and placed cir-
cumferentially at equal intervals under and around the
electrodes. This arrangement of the magnets is depicted
in Figure 2. The magnetic induction lines generated by
these permanent magnets traverse through the weld nug-
get, creating a Lorentz force.
14–16
By introducing perma-
nent magnets with different surface magnetic induction
intensities (referred to as B), the strength of the intro-
duced magnetic field was adjusted, thereby altering the
Lorentz force. The B value of the welding position was
measured by a HT-20 Gauss meter. This experimental
set-up allowed for an examination of how different B
values influenced the microstructure and tensile proper-
ties of the welded joints. The welding process parame-
ters are detailed in Table 3, with five welding tests con-
ducted for each set of welding parameters.
X. ZHU et al.: MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED ...
Materiali in tehnologije / Materials and technology 58 (2024) 4, 451–457 453
Figure 2: Schematic diagram of the MA-RSW process
Table 4: Cross-section macromorphology
Macromorphology Horizontal joint contact interface
0 mT 4.86 mm
20 mT 5.14 mm
40 mT 5.5 mm
60 mT 5.71 mm
80 mT No weld nugget

Table 3: Welding process parameters
Group
B of welding
position
Welding cur-
rent
Weld
time
Electrode
pressure
10 m T
11.0 kA 0.04 s 3.0 kN
22 0 m T
34 0 m T
46 0 m T
58 0 m T
After welding, metallographic samples were initially
cut from the welded joints by wire cutting. Then, sam-
ples were ground and polished using an MP-2B
metallographic specimen grinding and polishing ma-
chine equipped with double discs and a feature of
stepless speed change. Polished and ground samples
were etched in a solution of 5 mL nitric acid, 1 mL HF,
and 44 mL water for 12 s at room temperature to reveal
the cross-sectional macro-morphology of the welded
joints as well as the microstructure at the center and edge
of the weld nugget. The cross-sectional macro-morphol-
ogy of the welded joint was observed using a Zeiss
Stemi 508 stereomicroscope, and the size of the weld
nugget was recorded. The microstructures of the
weld-nugget center and edge were examined using a
Zeiss SIGMA 300 field emission scanning electron mi-
croscope (FESEM). The shear tensile loads (kN) and ex-
tension lengths (mm) of the RSW and MA-RSW joint
specimens obtained with different welding parameters
were measured using a CMT5305 electronic universal
testing machine at room temperature. For each set of
welding parameters, the average values of the maximum
shear tensile load and extension length were calculated
from the testing of three specimens. Prior to testing, (1 ×
20 × 20) mm and (1.5 × 20 × 20) mm steel plates were
placed respectively on the two end surfaces of the 7075
and 6082 sides of the welded joints to ensure a uniform
load during the tensile testing. After fracture of the
welded joints, Zeiss SIGMA 300 FESEM was employed
to evaluate the fracture morphology.
3 RESULTS AND DISCUSSION
Table 4 demonstrates that no apparent welding de-
fects, including shrinkage cavities, hot cracks, and/or in-
complete fusion, were observed across the cross-sections
of the welded joints produced using the five sets of weld-
ing parameters. Notably, when B was set at (0, 20, 40,
and 60) mT, a weld nugget with a semi-elliptical shape
was consistently observed, indicating successful weld-
ing. However, at a B of 80 mT, no weld nugget was de-
tected. This significantly reduced the mechanical proper-
X. ZHU et al.: MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED ...
454 Materiali in tehnologije / Materials and technology 58 (2024) 4, 451–457
Figure 4: Microstructure of the weld-nugget edge (FESEM): a) RSW
(B = 0 mT) and b) MA-RSW (B = 60 mT)
Figure 3: Microstructure of the weld-nugget center (FESEM):
a) RSW (B = 0 mT) and b) MA-RSW (B = 60 mT)

ties of the welded joints.
2–4
In addition, measurements
revealed a gradual increase in the weld nugget size with
increasing B values, with the largest nugget diameter of
5.71 mm observed at the B of 60 mT, representing a
17.5 % increase compared to the B of 0 mT (4.86 mm).
The observed phenomenon could be attributed to the
interaction between the external magnetic field and
welding current, resulting in the generation of a cir-
cumferential Lorentz force. This force promoted the cir-
cumferential movement of the molten metal within the
weld nugget. The Lorentz force increases monotonically
from the center to the edge of the nugget, pushing mol-
ten metal from the weld center to the periphery. This pro-
cess effectively enlarges the size of the weld nugget and
optimally utilizes the heat generated during RSW.
14–16
As indicated in the literature,
18–20
the magnitude of
the Lorentz force is directly proportional to B. Hence, a
higher B corresponds to a stronger Lorentz force, leading
to a more pronounced outward expansion of molten
metal and an increase in the nugget size. However, an ex-
cessively high B can result in an overly vigorous cir-
cumferential movement of the inner-nugget metal during
solidification, making it challenging to form a whole
weld nugget. This situation is not conducive to improv-
ing the mechanical properties of a welded joint. There-
fore, selecting an appropriate B value is crucial for im-
proving the microstructure of aluminum alloy RSW
joints.
During RSW, the nugget metal within the weld area
experienced resistance heat, causing it to reach the
liquidus temperature and melt completely. Subsequently,
the molten metal was forged and rapidly cooled. Due to
varying solidification conditions across different parts of
the weld during cooling, two distinct as-cast microstruc-
tures were observed in the weld-nugget center and nug-
get edge of the RSW and MA-RSW joints.
26–27
At the
center of the weld nugget, an equiaxed structure was de-
tected, with the grain size ranging from 3 μm to 6 μm,
and 1 μm to 5 μm, respectively, as depicted in Figure 3.
On the other hand, the edge of the weld nugget exhibited
a columnar dendritic structure aligned along the direc-
tion of the heat flow during solidification, with the width
ranging from 1.8 μm to 3.5 μm, and 1.2 μm to 2 μm, re-
spectively, as shown in Figure 4. Furthermore, the grain
size at the weld-nugget center was slightly larger than
that of the weld-nugget edge, aligning with the previous
research findings by Wu et al.
26–27
Upon observation, it was noted that the size of the
grains in the center and the edge of the nugget decreased
by approximately 41.1 and 46.7 %, respectively, after the
addition of magnetic field (B = 60 mT). This reduction
could be attributed to the generated Lorentz force, which
promoted the circumferential movement of the molten
metal within the weld nugget, consequently accelerating
the cooling rate of the weld. As a result, the MA-RSW
weld grain structure was refined, indicating a potential
improvement in the mechanical properties of the welded
joint.
Figure 5 presents the average recorded results for the
tensile shear load and extension length for four sets of
welded joints obtained with different welding parame-
ters. In all cases, fracture occurred at the weld. Both the
average tensile shear load and extension length increased
with the enhancement of B when the magnetic field
ranged from 0 mT to 60 mT, reaching their peak values
X. ZHU et al.: MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED ...
Materiali in tehnologije / Materials and technology 58 (2024) 4, 451–457 455
Figure 6: Fracture morphology: a) RSW (B = 0 mT) and b) MA-RSW
( B=6 0m T ) Figure 5: Tensile properties

a tB=6 0m T .Compared toB=0m T ,t h ea v erage tensile
shear load increased from 1.665 kN to 2.495 kN, mark-
ing a 49.8 % increase, while the extension length in-
creased from 1.603 to 2.097 mm, representing a 30.8 %
increase. This increase could be ascribed to the enlarged
weld-nugget size induced by the Lorentz force. Further-
more, the presence of the magnetic field contributed to
the grain refinement of both the weld-nugget center and
edge, which also significantly improved the tensile prop-
erties of the welded joints. These findings were in line
with the observed and analyzed results of the welded-
joint structures from Table 4 and Figures 3 and 4.
The fracture morphologies of RSW (B = 0 mT) and
MA-RSW (B = 60 mT) joints of the 7075 aluminum
plate are shown in Figure 6. Upon closer inspection, it
was observed that both welded joints failed by brittle
fracture, with a minor presence of ductile fracture. Re-
garding the RSW joints, the dimples on the fractured sur-
face were relatively shallow due to a small nugget size
and a coarser grain microstructure of the weld, leading to
brittle fracture and significantly reduced mechanical
properties of the welded joint (Figure 6a). On the other
hand, regarding the MA-RSW joints, a larger nugget size
and finer grain microstructure of the weld resulted in rel-
atively deeper fracture dimples. Therefore, the tensile
properties of the welded joints were improved. Although
the fracture of the welded joint remained brittle, the plas-
tic toughness was comparatively improved (Figure 6b),
indicating that the MA-RSW joint could achieve rela-
tively good comprehensive mechanical properties. These
findings further validated the results of the analysis pre-
sented in Figure 5.
4 CONCLUSIONS
The present study dealt with RSW of dissimilar alumi-
num alloys (6082 and 7075) using thermal compensation
and a steady-state magnetic field. The effects of different
B values on the macro-morphology, microstructure, ten-
sile properties, and morphology of the fractured surfaces
of the welded joints were systematically compared, lead-
ing to the following conclusions:
(1) Welded joints with imperceptible welding defects
were achieved using the two welding methods, both re-
sulting in a semi-elliptical nugget within a welded joint.
When B ranged from 0 mT to 60 mT, the generated Lo-
rentz force facilitated the circumferential movement of
molten metal, leading to an expansion of the weld-nug-
get size with increasing B. This indicated that the addi-
tion of magnetic field significantly improved the heat uti-
lization efficiency in RSW. However, ataBo f8 0m T ,
the excessive promotion of circular motion of molten
metal by the Lorentz force resulted in an absence of the
weld nugget within the weld. Thus, it is crucial to select
an appropriate B to promote the improvement of the
welded-joint microstructure.
(2) At B values of 0 mT and 60 mT, the micro-
structure between the edge and the center of a weld nug-
get exhibited columnar dendrite and equiaxed character-
istics, respectively. The introduction of the magnetic
field accelerated the outward circumferential movement
of molten metal via the Lorentz force, leading to an in-
creased cooling rate of the weld nugget and weld grain
refinement. Consequently, the grain size at the center and
edge of the weld nugget (B = 60 mT) decreased by
41.1 % and 46.7 %, respectively.
(3) As B increased, the Lorentz force played a more
significant role in increasing the weld-nugget size and
refining the weld grains. Consequently, the tensile prop-
erties of MA-RSW joints improved with increasing B.
Specifically, at the B of 60 mT, the average peak load
reached 2.495 kN, and the extension length measured
2.097 mm, marking a 49.8 % and 30.8 % improvement,
respectively, compared to the traditional RSW welded
joints. This indicated superior tensile properties. Addi-
tionally, the fracture dimples of the welded joints were
relatively deep, and the mechanical properties were sig-
nificantly improved. Overall, comprehensive results sug-
gested that the optimal comprehensive mechanical prop-
erties of MA-RSW joints were achieved at the B of
60 mT.
Acknowledgments
The authors would like to acknowledge the support
from the Basic Scientific Research Project of Liaoning
Provincial Department of Education (grant number:
JYTMS20230848), the Basic Scientific Research Project
of Liaoning Provincial Department of Education (grant
number: JYTMS20230846) and the Doctoral Start-Up
Foundation of Liaoning Province (grant number:
2023-BS-195).
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