Optimization of welding parameters for resistance spot welding of TRIP steel with response surface methodology

Resistance spot welding (RSW) with inserted strips, a recent variant of traditional RSW, was usually adopted in joining thin gage steels to lower the temperature developed at the electrode surface and to extend electrode life. In order to understand the influencing mechanism how the inserted strips affect the heat transfer behavior and to optimize the selection of suitable strips, an approach integrated with FEM and response surface methodology (RSM) was employed. FEM results showed that the inserted strips would not only lead to earlier initiation of weld and bigger weld size in both diameter and thickness but also lower the electrode surface temperature. Based on FEM, uniform design and RSM were further employed to build a regression model between the strip properties (i.e., electrical/thermal conductivity, thickness) and the responses (i.e., electrode tip temperature, weld diameter, and temperature at strip/sheet interface). A graphical optimization was conducted to identify a preferable strip, and a Cu55Ni45 strip with a thickness of 0.12 mm was recommended for a 0.4 mm steel sheet.

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Optimization of the Resistance Spot Welding Process of 22MnB5-Galvannealed Steel Using Response Surface Methodology and Global Criterion Method Based on Principal Components Analysis

Metals ◽

10.3390/met10101338 ◽

2020 ◽

Vol 10 (10) ◽

pp. 1338

Author(s):

Robson Ribeiro ◽

Estevão Luiz Romão ◽

Eduardo Luz ◽

José Henrique Gomes ◽

Sebastião Costa

Keyword(s):

Response Surface Methodology ◽

Response Surface ◽

Principal Components ◽

Resistance Spot Welding ◽

Spot Welding ◽

Resistance Spot ◽

Global Criterion ◽

Global Criterion Method ◽

Criterion Method ◽

Galvannealed Steel

The 22MnB5-galvannealed steel is extensively used in the hot stamping process to produce car anti-collision structure parts. Furthermore, the resistance spot welding (RSW) is an important process in the automobile industry, especially in body construction, and the 22MnB5-galvannealed steels are a big challenge for the joining methods because their microstructure and mechanical properties are different from those of the conventional steels. In view of this, the present paper aims to optimize the parameters of the RSW process of the 22MnB5-galvannealed steel. Initially, the goal was to remove the galvannealed coating and in the next stage, the following responses were maximized: the nugget width, the nugget cross-sectional area, the penetration, the strength, the joint efficiency, and the energy absorption, whereas the indentation, heat affected zone and separation were used as constraints. The process parameters selected were the effective welding time, the effective welding current, the quenching time, and the upslope time. Response surface methodology (RSM) was applied jointly with the global criterion method based on principal components. The results of the multiobjective optimization are close to the individual targets for each response, highlighting the importance of considering the correlation structure presented in the responses.

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Optimization on Spot Weld Parameters in Resistance Spot Welding Process on AISI 304

International Journal of Engineering and Management Research ◽

10.31033/ijemr.11.3.29 ◽

2021 ◽

Vol 11 (3) ◽

pp. 181-185

Author(s):

Amit Hazari ◽

Rith Saha ◽

Bidisha Ghosh ◽

Debraj Sengupta ◽

Sayan Sarkar ◽

...

Keyword(s):

Resistance Spot Welding ◽

Spot Welding ◽

Welding Process ◽

Welding Current ◽

Electrical Current ◽

Industrial Applications ◽

Spot Weld ◽

Welding Parameters ◽

Resistance Spot ◽

Weld Time

The spot welding procedure is used in a variety of industrial applications. The most critical elements influencing welding quality, productivity, and cost are the spot welding parameters. This research examines the effect of welding factors such as welding current and welding time on the strength of various welding joint designs. Resistance spot welding (RSW) is used in the automotive industry for manufacturing. This research focused on the optimization of process parameters for resistance spot welding (RSW), as well as the tensile testing and spot weld diameter. The goals of this analysis are to comprehend the physics of the process and to demonstrate the effect of electrical current, weld time, and material type on the resistance spot welding process.

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