Modeling and Optimization of Weld Zone Development in Resistance Seam Welding

Abstract

Resistance Seam Welding (RSEW) is an ideal welding method to produce airtight joints where welding input parameters play a very significant role in determining the quality of weld nugget and heat affected zone (HAZ) formation. This research is aimed to study the nugget and HAZ development of 1 mm low carbon steel using RSEW. Welding parameters such as weld current, weld time, weld speed and pressure were identified and investigated to study their effect on the formation of weld nugget by using 2 4 factorial designs. The objective of this work is to find the optimum parameter to optimize the width of weld nugget and HAZ in order to obtain a good quality of RSEW. Furthermore the mathematical models were developed to predict the weld zone development. Experimental confirmation test was conducted at an optimal condition for observing accuracy of the developed model. Based on the confirmation test, the proposed method can be effectively used to predict the size of weld zone which can improve the welding quality and performance in RSEW.