Parametric Optimization of Resistance Spot Welding to Improve the Weld Strength

Abstract

This research offers important insights in to enhance spot welded joint strength with practical applications across a wide range of industries. Galvanized steel sheets, prized for their corrosion resistance and extensive use in various applications, serve as the base material. L27 is used to study design and process parameters (electrode force and welding current) systematically. The tensile shear and tensile loading conditions are rigorously tested on universal testing machines using specially designed fixtures. The regression modelling technique is used in the study to determine the mathematical relationship between welding characteristics and joint strength. The Taguchi method and an ANOVA are used to determine the critical parameters and the signal to noise ratio helps to identify the best welding parameter combinations. The correlation between the experimental results and the regression analysis confirms the robustness of the models produced. In order to achieve significant gains in tensile shear and tensile strength, the research closes by showing the best combinations for lap shear and cross tension specimens.