Resistance Spot Brazing Workpiece Stack-Ups Having One Or More Thin-Gauge Steel Workpieces

A method of resistance spot brazing a workpiece stack-up, the method comprising:

• providing a first thin-gauge steel workpiece and a second thin-gauge steel workpiece;
• applying a filler material to a first surface of the first thin-gauge steel workpiece;
• depositing a plurality of particles into the applied filler material;
• adjoining a second surface of the second thin-gauge steel workpiece to the filler material;
• clamping a first welding electrode and a second welding electrode on the first and second thin-gauge steel workpieces adjacent the filler material, the plurality of particles facilitating a retained gap dimension at the filler material between the first and second surfaces as the first and second welding electrodes exert a clamping load thereat;
• passing electrical current between the first and second welding electrodes;
• and
• terminating passage of the electrical current to establish a brazed joint between the first and second thin-gauge steel workpieces.

A method of resistance spot brazing a workpiece stack-up, the method comprising:

• providing a first thin-gauge steel workpiece and a second thin-gauge steel workpiece, wherein the first thin-gauge steel workpiece has a thickness dimension that is less than approximately 0.75 millimeters (mm), and the second thin-gauge steel workpiece has a thickness dimension that is less than approximately 0.75 mm;
• applying a filler material to a first surface of the first thin-gauge steel workpiece via additive manufacturing;
• depositing a plurality of particles into the applied filler material via thermal spraying;
• adjoining a second surface of the second thin-gauge steel workpiece with the applied filler material having the deposited particles;
• clamping a first welding electrode and a second welding electrode on the first and second thin-gauge steel workpieces adjacent the filler material, the plurality of particles facilitating a retained gap dimension at the filler material between the first and second surfaces as the first and second welding electrodes exert a clamping load thereat;
• passing electrical current between the first and second welding electrodes;
• and
• terminating passage of the electrical current to establish a brazed joint between the first and second thin-gauge steel workpieces.