US Patent 10335892 Weld electrode for attractive weld appearance

A welding electrode for use in resistance spot welding an assembly of overlying metal workpieces that includes an aluminum alloy workpiece is disclosed. The welding electrode includes a body, a convex weld face at one end of the body, and ringed protrusions that project outwardly from the convex weld face. The ringed protrusions are positioned to make contact with, and indent into, a surface of the aluminum alloy workpiece when the convex weld face is pressed against the aluminum alloy workpiece during a spot welding event. When brought into contact with the surface of the aluminum alloy workpiece, the ringed protrusions disrupt the oxide film present on the aluminum alloy workpiece surface, which improves the spot welding process.