An Experimental Investigation of the Effect of Spot-Welding Process Parameters on the Braking Load of Similar Metal Joints

Abstract

Applied in automotive, aerospace, and structural applications needing high welding quality and mechanical performance, resistance spot welding (RSW) is a critical connecting method. The effects of welding pressure on the tensile strength of the most important RSW process parameters—that of welding stream, compressed time, welding time, retention time, and low tolerance (HSLA) high strength 355 steel connections—are investigated in this work. 22 experimental studies in all were carried out using Response surface method and a pneumatically controlled resistance welding machine with a box 10 configuration. Joint resistance is shown to be most influenced by weld current, retention time, and welding time in experimental findings. Maximum tensile strength of 1.152 kN/mm² came from optimized welding settings for 6 ka welding current, hold times of 14 ms, 25 ms, and 4 kN welding pressure. Advanced prediction models including artificial neural networks (ANNs) and finite element analysis (FEAs) will be used in next work to enhance parameter selection and process efficiency