The nugget size is larger in the spot welds with adhesive but the maximum load carrying capacity is unaffected.

X-ray computed tomography shows main fatigue crack initiates at the edge of the nugget and penetrates through the thickness of Aural2 sheet.

All structural stress range-fatigue life data fall onto a master curve indicating nugget size dominates the fatigue life.

Adhesive-induced porosity within the weld nugget does not harm fatigue performance.