This work considers the possibility to apply the improved hybrid Capacitor Discharge Welding process (CDW), based on projection Welding principles, to aluminium alloy Al 5754. The innovative aspects are the effective possibility to weld aluminium alloys with CD Welding process and establish the mechanical weld characteristics and defects presence as function of the technological parameters. Intrinsic CDW process characteristics need to be investigated on the base of interaction between the technological aspects and the related mechanical properties. The geometrical and technological factors are combined to improve the welding efficiency and reduce defects size. In order to assess the technological parameters, visual and ultrasonic inspection of the most significant welded joints were performed and room temperature tensile and fatigue tests were executed to verify the welding results.
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