Optimization of resistance spot welding process applied to A36 mild steel and hot dipped galvanized steel based on hardness and nugget geometry

Resistance spot welding (RSW), a process intensively used for thin metal sheets assembly in automotive, railway, and aeronautical industries, has always presented technical and economic challenges. Thermal distortions and difficulties caused by the presence of anticorrosive coating on galvanized ste...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2020, Vol.106 (5-6), p.2477-2491
Main Authors: Feujofack Kemda, B. V., Barka, Noureddine, Jahazi, M., Osmani, D.
Format: Article
Language:English
Subjects:
Aeronautics
CAE) and Design
Computer-Aided Engineering (CAD
Corrosion prevention
Engineering
Galvanized steel
Galvanized steels
Galvanizing
Hardness tests
Hot dipping
Industrial and Production Engineering
Low carbon steels
Mechanical Engineering
Media Management
Metal sheets
Microhardness
Optimization
Original Article
Resistance spot welding
Response surface methodology
Steel industry
Variance analysis
Welded joints
Welding parameters
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Summary:Resistance spot welding (RSW), a process intensively used for thin metal sheets assembly in automotive, railway, and aeronautical industries, has always presented technical and economic challenges. Thermal distortions and difficulties caused by the presence of anticorrosive coating on galvanized steels are among the major issues. An evaluation of effects of welding parameters on overall nugget quality will be of great importance in solving these issues. Two grades of steel were used in this study, A36 mild steel and A653 hot dipped galvanized steel. Welding experiments were done in overlap configuration, grade for grade, while following complete factorial plans of three factors at two levels. Micrographic analyses revealed weld microstructure, while micro-indentation hardness tests enabled to establish the hardness profile along weld nuggets. Analyses of variance (ANOVA) were done in order to evaluate the effect of each parameter on nugget hardness and diameter. Response surface models combining hardness in the fusion zone and nugget diameter were plotted as function of welding parameters. These response surfaces showed that current is the predominant parameter and should be maximized in order to achieve strong welds while force and time should be minimized for A36 mild steel and maximized for galvanized steel.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-019-04707-w