Date of Award


Publication Type

Master Thesis

Degree Name



Mechanical, Automotive, and Materials Engineering


Engineering, Materials Science.




Brass layer formation and hardness degradation during the resistance spot welding of hot-dipped galvanized steel was characterized for a number of copper-based electrode materials and electrode geometries as part of an overall program to increase electrode life through the analysis of electrode wear. Metallographic, composition, and hardness examinations were conducted on electrodes subjected to single-current and stepped-current life tests. The electrode wear sequence was documented via sequential life testing, in which electrodes were removed for testing and examination at established intervals during single-current testing. Testing was conduced on truncated-cone and ball-nose electrode geometries. Electrode materials included a Class 2 precipitation-hardened copper-zirconium, as well as two new proprietary electrode materials: one precipitation hardened, and the other second phase strengthened. Characterization included the effect of electrode geometry and composition on alloying and hardness retention. (Abstract shortened by UMI.) Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2005 .A845. Source: Masters Abstracts International, Volume: 44-03, page: 1478. Thesis (M.A.Sc.)--University of Windsor (Canada), 2005.