Optimization the Resistance Spot Welding Parameters of Austenitic Stainless Steel and Aluminum Alloy Using Design of Experiment Method

Abstract

This research aims to study the effect of RSW parameters on the sheer force of the spot welded for two materials {AISI 304L and AA 6061-T6} with (0.5 and 0.7 mm) thickness. Three values for each welding parameters (welding current, electrode force, squeeze time and welding time) are to be used. The effect of those parameters has been analyzed by using design of experiments (DOE) in order to determine and reduce the number of the tested specimens. The experimental tests have been done that are; shear, micro hardness tests and microstructure examination. It was found that the maximum shear force in welding of similar material AISI 304L is (F = 4.78 KN for t = 0.7 mm), while in the joint of dissimilar material (AA 6061-T6 with AISI 304L), the maximum shear force is (F = 1.42 KN for t = 0.7 mm). These values have been optimized to reach (F =5.13 KN & F =1.54 KN) respectively by using DOE. The minimum shear force was (F = 0.07 KN in t = 0.5 mm). It was found that, increasing the welding current and sheet thickness gave an increase in the shear force, but at the same time the reduction in shear force has occurred during the increasing in electrode force, squeeze time and welding time. From micro hardness tests, it was found that the maximum value of hardness was at the center of nugget zone (NZ) and it reduces slightly until reaching constant values away from nugget zone.

Effect of Welding Time Variation in Resistance Spot Welding on Mechanical Properties of Dissimilar Joints on Mild Steel and AISI 304 Stainless Steel

“…With increasing welding time, higher tensile strength is obtained, this is because the heat input that occurs is also greater, resulting in a strong tensile strength. But the connection is not always better, in the dissimilar metal point weld connection there is a condition where at 8 seconds the tensile strength decreases, this happens because the heat input exceeds the melting point of the material used so as to produce a wide weld metal area and deep penetration area, then the welding result will be damaged [19][20][21].…”

Investigating Spot Weld Fatigue Failure with Experimental and Finite Element Analysis Methods

“…The RSW specimens were gripped with alignment tabs of a thickness equal to that of the specimens to ensure that the tensile force was applied to the weld spot and to avoid bending [47]. The average values have been taken from different measurements.…”

Analysis of double resistance spot welding's failure in high strength low alloy steel

“…The findings demonstrated that increasing the sheet thickness and welding current sheet thickness raised the strength of the welded components. Strength of welded parts decreased as electrode force and welding time were increased [21]. In contrast to past studies, which focused on a single area, the current work proposes a double RSW optimization strategy for high strength steel low alloys (DOCOL 500 LA).…”