In this study, experiments without interlayers and with interlayers of copper and stainless-steel sheets were performed. Design of Experiments based Full-Factorial Method was employed to generate experimental combinations. A total 81 samples were welded and tested in Universal Testing Machine to determine their Breaking Load. To investigate feasibility considering vehicle lightweightness, a novel LTW (Load-to-Weight) ratio has been proposed. Calculated LTW ratio for each experiment clearly showed that samples with stainless-steel interlayer outperformed over samples with copper interlayer and samples without interlayer. For feasibility in terms of machine durability, electrode corrosion has been found as the most auspicious parameter among all. Spot welding electrodes attain air oxidation above 700 °C. An FEA solver has been employed to determine time for electrodes to remain above air oxidation temperature during a single welding cycle through numerical simulation. A novel LTT (Load-to- Time) ratio has been proposed to find experimental combinations considering feasibility regarding electrode corrosion. LTT ratio, applied to experimental combinations with SS interlayer helped in selection of suitable process parameter combinations. Selected combinations through LTW and LTT ratio can be further proposed to industries. Study advocates method to calculate LTW ratio initially, following calculation of LTT ratio and eventually selecting process parameters contemplating feasibility in lightweightness and electrode corrosion. Article Highlights Study helps to decide feasibility of interlayer in RSW in terms of weight and electrode corrosion. Load-to-Weight (LTW) ratio is proposed to decide feasibility of interlayer in terms of weight. Load-to-Time (LTT) ratio is proposed to determine feasibility of interlayer against electrode corrosion.

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Metal castings with the presence of shrinkage porosity are often recycled or rejected and in turn reduce productivity of the process as well as increase energy cost involved in the process. This can be overcome by prevention of its occurrence using a suitable prediction technique. A detailed study of literature reveals that several Criterion Functions (an empirical model that connects solidification phenomena with formation of shrinkage porosity) have been employed to predict the location of shrinkage porosity in castings manufactured using particular process-alloy combination by values of process parameters (mostly thermal gradient, cooling rate, and velocity of molten metal). However, criterion function considering the effect of geometric variation in stainless steel castings on an extent of shrinkage porosity need to be established. In the present work, a benchmark casting, a combination of three T junctions, has been cast and used for the development of geometry-driven criterion function for stainless steel castings. Real experimental results with the presence of shrinkage porosity were used for superimposing on virtual experimental results (simulated results) for establishment of local simulation conditions. These conditions are further used in extrapolating results using casting simulation. The developed geometry-driven criterion function was further validated and found to be effective in prediction of shrinkage porosity.