This invention presents an RSW electrode cost saving solution for resistance spot welding of aluminums, including apparatus with automation, ablation process and method. It is achieved by cleaning with a laser ablation process that minimizes the metal removal amount each time compared to a current mechanical electrode dressing method (Laser ablation 0.02mm vs electrode dressing 0.2mm). To make it effective and reproductive, the laser ablation process is preferably performed on the welding electrode prior to serious electrode sticking. RSW on various aluminum grades and joint stacks have been tested and validated in a lab scale, it has shown that the electrode life with laser ablation lasts at least 10 times longer in total than that of current electrode dressing method.
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Wu, Feng; Lin, Yan; Malpica, Julio; de Moraes, Joao Felipe Carvalho; Lin, Dechao; Duan, Jinwen (Kevin); and Wang, Tao (Atom), "Laser Ablation of Electrode to Extend RSW Electrode Life and Save Production Cost", Technical Disclosure Commons, (November 09, 2023)