Determination of corrosion behavior of aluminum and stainless steel materials joined by spot welding method

In this study, the corrosion behavior of aluminum 5083 and austenitic stainless steel AISI 304, AISI 304L materials joined by the resistance spot welding method has been investigated. The combination of different materials in engineering applications has become increasingly important due to the unique properties and cost considerations of each material, and it is becoming more widespread every day. However, the occurrence of corrosion between these materials must be taken into account because it can affect the overall structural integrity and durability. This study aims to comprehensively evaluate the corrosion behavior of such hybrid structures, with a particular focus on the effects of the resistance spot welding method. This thesis work involves creating hybrid specimens by resistance spot welding aluminum and stainless steel materials, representing real-world applications, at two different currents. ASTM G48 tests were conducted on these specimens to examine their corrosion behavior. The corrosion effects occurring at the weld interface were also assessed as a result of these tests. Experimental results were analyzed to determine the corrosion rates and trends of hybrid structures. Additionally, the influence of spot welding parameters such as welding current on corrosion behavior was investigated. Furthermore, corrosion effects on the specimens were examined using optical microscopes and scanning electron microscopy (SEM). The findings of this study provide insight into the corrosion behavior of hybrid aluminum 5083 H111 and austenitic stainless steel AISI304-AISI304L structures joined by the resistance spot welding method. In conclusion, the study of the corrosion behavior of hybrid aluminum and stainless steel materials joined by the spot welding method provides valuable information for the design and manufacturing processes of structures where these materials are used together. Keywords: Dissimilar metals welding, corrosion behaviors, resistance spot welding, AA5083, AISI 304, AISI 304L.