The nugget formation of resistance spot welding (RSW) on dissimilar material sheets of aluminum and magnesium alloys was studied, and the element distribution, microstructure, and microhardness distribution near the joint interface were analyzed. It was found that the staggered high regions at the contact interface of aluminum and magnesium alloy sheets, where the dissimilar metal melted together, tended to be the preferred nucleation regions of nugget. The main technical problem of RSW on dissimilar metal sheets of aluminum and magnesium alloys was the brittle-hard Al12Mg17 intermetallic compounds distributed in the nugget, with hardness much higher than either side of the base materials. Microcracks tended to generate at the interface of the nugget and base materials, which affected weld quality and strength.
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