Optimization of Resistance Spot Welding Parameters for 316L Stainless Steel Using Response Surface Methodology and Box-Behnken Design: Investigation on Joint Characteristics and Performance

Abstract

Resistance spot welding (RSW) is a commonly utilized method for the fusion of metals in diverse sectors such as automotive, aerospace, and manufacturing. The present study aims to examine the significant impact of process parameters in the Resistance Spot Welding (RSW) technique on the properties and effectiveness of joints created in sheets of 316L stainless steel. 316L stainless steel is widely recognized for its exceptional resistance to corrosion and impressive mechanical qualities, rendering it a highly favoured material for applications that require utmost reliability and performance. The study commences by investigating the impact of crucial resistance spot welding (RSW) process parameters, including welding current, welding time, and electrode force, on the properties of the joint. A comprehensive parametric investigation is undertaken to get insight into the influence of parameter variations on the microstructure, nugget size, and heat-affected zone (HAZ) of the welded joints. The significance of welding current is particularly highlighted, with an emphasis on its function in regulating the size of the weld nugget and the subsequent strength of the connection. The evaluation of mechanical performance plays a crucial role in understanding the effectiveness of welded joints. This study aims to provide a comprehensive analysis of the tensile strength, shear strength, and fatigue parameters of resistance spot welded (RSW) joints. This study examines the impact of process parameters on the mechanical properties of joints, aiming to get a deeper understanding of the ideal circumstances necessary to achieve welds with superior strength and durability. In addition, the microstructural analysis elucidates the relationship between the welding parameters and the grain structure present in the joint region. Comprehending these microstructural alterations is vital in order to forecast and regulate the mechanical characteristics of the weldments. The results of this study hold significant importance for industries and applications that heavily depend on 316L stainless steel. They offer a comprehensive guide for enhancing resistance spot welding (RSW) procedures in order to achieve enhanced joint properties and overall performance. The findings derived from this study have the potential to contribute to the improvement of the dependability and durability of welded elements in high-stakes settings. This work makes a valuable contribution to the continuous endeavours aimed at enhancing the quality and efficiency of resistance spot welding (RSW) in 316L stainless steel applications by elucidating the complex correlation between welding parameters and joint quality.