Structural-adhesive-assisted DeltaSpot welding was used to improve the weldability and mechanical properties of dissimilar joints between 6061 aluminum alloy and galvannealed HSLA steel. Evaluation of the spot-weld-bonded surfaces from lap shear tests after long-term exposure to chloride and a humid atmosphere (5% NaCl, 35 °C) indicated that the long-term mechanical reliability of the dissimilar weld in a corrosive environment depends strongly on the adhesive-Al6061 alloy bond strength. Corrosive electrolyte infiltrated the epoxy-based adhesive/Al alloy interface, disrupting the chemical interactions and decreasing the adhesion via anodic undercutting of the Al alloy.
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