Resistance spot welding manufacture and method of forming same

A resistance spot welding manufacture comprising:

• a first metal layer having a first thickness;
• a second metal layer having a faying surface defining an embossed region, wherein said second metal layer has a second thickness that is less than said first thickness so that a ratio of said first thickness to said second thickness is greater than about 2:1;
• a third metal layer sandwiched between said first metal layer and said embossed region such that said third metal layer is disposed adjacent to and in contact with each of said first metal layer and said second metal layer, wherein said third metal layer has a third thickness that is greater than said second thickness;
• wherein each of said first metal layer, said second metal layer, and said third metal layer is formed from steel including carbon;
• wherein an amount of carbon present in said second metal layer is less than an amount of carbon present in either of said first metal layer and said third metal layer;
• and
• a weld joint penetrating each of said first metal layer, said third metal layer, and said faying surface at said embossed region to thereby join each of said first metal layer and said second metal layer to said third metal layer.

A resistance spot welding manufacture comprising:

• a first metal layer having a first thickness;
• a second metal layer having a faying surface defining an embossed region, wherein said second metal layer has a second thickness that is less than said first thickness;
• a third metal layer sandwiched between said first metal layer and said embossed region such that said third metal layer is disposed adjacent to and in contact with each of said first metal layer and said second metal layer, wherein said third metal layer has a third thickness that is greater than said second thickness;
• and
• a weld joint penetrating each of said first metal layer, said third metal layer, and said faying surface at said embossed region to thereby join each of said first metal layer and said second metal layer to said third metal layer;
• wherein a ratio of said third thickness to at least one of said first thickness and said second thickness is greater than about 3:1.