Optimization of Resistance Spot Welding Process Parameters for Mild Steel/Aluminium Joints with Cover Plate Based on Tensile Shear Strength
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Date
2023-08-01
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G.B. Pant University of Agriculture and Technology, Pantnagar-263145
Abstract
Resistance spot welding (RSW) is a widely used method for joining similar and
dissimilar metals, often enhanced with a cover plate. This study focuses on optimizing
the RSW process parameters to achieve improved Tensile Shear Strength (TSS) in such
joints. The key factors under investigation are welding current, welding time, and
electrode pressure. The Taguchi methodology, a robust optimization technique, is
employed to design experiments and analyze the effects of the aforementioned factors
on TSS. This method allows for efficient exploration of the parameter space with a
limited number of experiments. Subsequently, Analysis of Variance (ANOVA) is
applied to ascertain the significance of each factor's influence on TSS
variation.Through a series of controlled experiments and systematic analysis, optimal
levels of welding current, welding time and electrode pressure are determined. The
findings of this research offer valuable guidance resistance spot welding of mild
steel/aluminium joints with cover plates. By enhancing Tensile Shear Strength through
optimized process parameters, the study ultimately contributes to the development of
more reliable and durable joint configurations in industrial applications.Optimum levels
of the various process parameters include welding current (3) 15.6 kA, electrode force
(1) 3.79 bar, and welding cycle time (3) 55 for maximum tensile strength.
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