Tensile shear load in resistance spot welding of dissimilar metals: An optimization study using response surface methodology
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Sep 11, 2023
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Abstract
Resistance spot welding (RSW) is being applied extensively in different industries, specifically the automotive sector. Therefore, this study was conducted to optimize the tensile strength load (TSL) in RSW by investigating the application of dissimilar materials as input parameters. The optimization process involved the combination of different galvanized and non-galvanized steel materials. The production of car bodies using galvanized steel with approximately 13.0 microns thick zinc (Zn) coating was found to be a standard practice, but this zinc layer usually presents challenges due to the poor weldability. This study prepared 27 units of TSL samples using a spot-welding machine and a pressure force system (PFS) for the electrode tip. The aim was to determine the optimal TSL through the exploration of specified RSW parameters. The process focused on using the response surface methodology (RSM) to achieve the desired outcome while the Box-Behnken design was applied to determine the input parameters. The optimal TSL obtained was 5265.15 N by setting the squeeze time to 21.0 cycles at a welding current of 24.5 kA, a welding time of 0.5 s, and a holding time of 15.0 cycles. The highest TSL value recorded was 5937.94 N at 21.0 cycles, 27.0 kA, 0.6 s, and 15.0 cycles respectively. These findings were considered significant to the enhancement of productivity across industries, specifically in the RSW process. However, further study was required to investigate additional response variables such as the changes in hardness and microstructure.
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References
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[37] L. Jin-Hee, Bae.Yeong-Do, Park, Mokyoung, “Optimization of Welding Parameters for Resistance Spot Welding of AA3003 to Galvanized DP780 Steel Using Response Surface Methodology,” International Journal of Automotive Technology, vol. 22, no. 3, pp. 585–593, 2021.
[2] S. Sukarman et al., “Optimal Tensile-Shear Strength Of Galvanized/Mild Steel (SPCC-SD) Dissimilar Resistance Spot Welding Using Taguchi DOE,” Jurnal Teknologi, vol. 4, pp. 167–177, 2023.
[3] S. K. Khanna, C. He, and H. N. Agrawal, “Residual stress measurement in spot welds and the effect of fatigue loading on redistribution of stresses using high sensitivity Moiré interferometry,” Journal of Engineering Materials and Technology, Transactions of the ASME, vol. 123, no. 1, pp. 132–138, 2001, doi: 10.1115/1.1286218.
[4] S. H. M. Anijdan, M. Sabzi, M. Ghobeiti-hasab, and A. Roshan-ghiyas, “Materials Science & Engineering A Optimization of spot welding process parameters in dissimilar joint of dual phase steel DP600 and AISI 304 stainless steel to achieve the highest level of shear-tensile strength,” Materials Science & Engineering A, vol. 726, no. April, pp. 120–125, 2018, doi: 10.1016/j.msea.2018.04.072.
[5] Posco, “Automotive,” Posco, 2022. .
[6] S. Sukarman, A. Abdulah, D. A. Rajab, and C. Anwar, “Optimization of Tensile-Shear Strength in the Dissimilar Joint of Zn-Coated Steel and Low Carbon Steel,” Automotive Experiences, vol. 3, no. 3, pp. 115–125, 2020, doi: 10.31603/ae.v3i3.4053.
[7] B. Xing, Y. Xiao, Q. H. Qin, and H. Cui, “Quality assessment of resistance spot welding process based on dynamic resistance signal and random forest based,” International Journal of Advanced Manufacturing Technology, vol. 94, no. 1–4, pp. 327–339, 2018, doi: 10.1007/s00170-017-0889-6.
[8] Miller Handbook, Handbook for Resistance Spot Welding. Miller Electric Mfg. Co., 2010.
[9] E. Gunawan, S. Sukarman, A. D. Shieddieque, and C. Anwar, “Optimasi Parameter Proses Resistance Spot Welding pada Pengabungan Material SECC-AF,” no. September, 2019.
[10] D. L. Olson, S. Thomas A., S. Liu, and G. R. Edwards, Welding, brazing, and soldering, vol. 6. ASM International, 1990.
[11] X. Wan, Y. Wang, and D. Zhao, “Multi-response optimization in small scale resistance spot welding of titanium alloy by principal component analysis and genetic algorithm,” International Journal of Advanced Manufacturing Technology, vol. 83, no. 1–4, pp. 545–559, 2016, doi: 10.1007/s00170-015-7545-9.
[12] M. K. Wahid, M. N. Muhammed Sufian, and M. S. Firdaus Hussin, “Effect of fatigue test on spot welded structural joint,” Jurnal Teknologi, vol. 79, no. 5–2, pp. 95–99, 2017, doi: 10.11113/jt.v79.11290.
[13] N. K. Singh and Y. Vijayakumar, “Application of Taguchi method for optimization of resistance spot welding of austenitic stainless steel AISI 301L,” Innovative Systems Design and Engineering, vol. 3, no. 10, pp. 49–61, 2012.
[14] A. H. Ertas and F. O. Sonmez, “Design optimization of spot-welded plates for maximum fatigue life,” 2011, doi: 10.1016/j.finel.2010.11.003.
[15] H. Wiryosumarto and T. Okumura, Teknologi Pengelasan Logam, 8th ed. Jakarta: PT Pradnya Paramita, 2000.
[16] J. P. Oliveira, K. Ponder, E. Brizes, T. Abke, A. J. Ramirez, and P. Edwards, “Combining resistance spot welding and friction element welding for dissimilar joining of aluminum to high strength steels,” Journal of Materials Processing Technology, vol. 273, no. January, p. 116192, 2019, doi: 10.1016/j.jmatprotec.2019.04.018.
[17] S. T. Pasaribu, S. Sukarman, A. D. Shieddieque, and A. Abdulah, “Optimasi Parameter Proses Resistance Spot Welding pada Pengabungan Beda Material SPCC,” 2019, no. September.
[18] A. G. Thakur and V. M. Nandedkar, “Optimization of the Resistance Spot Welding Process of Galvanized Steel Sheet Using the Taguchi Method,” Arabian Journal for Science and Engineering, vol. 39, no. 2, pp. 1171–1176, 2014, doi: 10.1007/s13369-013-0634-x.
[19] S. Shafee, B. B. Naik, and K. Sammaiah, “Resistance Spot Weld Quality Characteristics Improvement By Taguchi Method,” Materials Today: Proceedings, vol. 2, no. 4–5, pp. 2595–2604, 2015, doi: 10.1016/j.matpr.2015.07.215.
[20] H. E. Emre and R. Kaçar, “Development of weld lobe for resistance spot-welded TRIP800 steel and evaluation of fracture mode of its weldment,” International Journal of Advanced Manufacturing Technology, Springer, vol. 85, pp. 1737–1747, 2016, doi: 10.1007/s00170-015-7605-1.
[21] K. Vignesh, A. E. Perumal, and P. Velmurugan, “Optimization of resistance spot welding process parameters andmicrostructural examination for dissimilar welding of AISI 316L austenitic stainless steel and 2205 duplex stainless steel,” International Journal of Advanced Manufacturing Technology, pp. 455–465, 2017, doi: 10.1007/s00170-017-0089-4.
[22] V. Kuklík and J. Kudláĉek, Hot-Dip galvanizing of steel structures. 2016.
[23] K. Khoirudin, S. Sukarman, N. Rahdiana, A. Suhara, and A. Fauzi, “Optimization of S-EDM Process Parameters on Material Removal Rate Using Copper Electrodes,” Jurnal Polimesin, vol. 21, no. 1, pp. 17–20, 2023.
[24] A. Abdulah and S. Sukarman, “OPTIMASI SINGLE RESPONSE PROSES RESISTANCE SPOT WELDING,” Multitek Indonesia: Jurnal Ilmiah, vol. 6223, no. 2, pp. 69–79, 2020.
[25] JIS G 3302, “JIS G 3302 Hot-dip zinc-coated steel sheet and strip.” Japanese Industrial Standard, 2007.
[26] JIS G3131, “Hot-rolled mild steel plates, sheet and strip.” 2010.
[27] American Welding Society, Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steel (AWS D8.9M:2012). 2012, p. 7.
[28] Miller Electric Mfg. Co., “Handbook for Resistance Spot Welding,” 2012.
[29] Y. G. Kim, D. C. Kim, and S. M. Joo, “Evaluation of tensile shear strength for dissimilar spot welds of Al-Si-Mg aluminum alloy and galvanized steel by delta-spot welding process,” Journal of Mechanical Science and Technology, vol. 33, no. 11, pp. 5399–5405, 2019, doi: 10.1007/s12206-019-1034-2.
[30] J. Pan and K. Sripichai, “Mechanics modeling of spot welds under general loading conditions and applications to fatigue life predictions,” Woodhead Publishing Limited, 2010, doi: 10.1533/9781845699765.1.
[31] Sukarman, C. Anwar, N. Rahdiana, and A. I. Ramadhan, “Analisis Pengaruh Radius Dies Terhadap Springback Logam Lembaran Stainless-Steel pada Proses Bending Hidrolik V-DIE,” Junal Teknologi, vol. 12, no. 2, 2020.
[32] P. J. Ross, Taguchi Techniques for Quality Engineering. New York: Tata McGraw-Hill, 2005.
[33] H. Arjmandi, P. Amiri, and M. Saffari Pour, “Geometric optimization of a double pipe heat exchanger with combined vortex generator and twisted tape: A CFD and response surface methodology (RSM) study,” Thermal Science and Engineering Progress, vol. 18, no. December 2019, p. 100514, 2020, doi: 10.1016/j.tsep.2020.100514.
[34] P. G. Mathews, Design of Experiments with MINITAB, 12th ed., vol. 60, no. 2. Milwaukee: Mathews, Paul G., 2005.
[35] F. A. Ghazali et al., Three Response Optimization of Spot-Welded Joint Using Taguchi Design and Response Surface Methodology Techniques, vol. 0. Springer Singapore, 2019.
[36] R. Ribeiro, E. L. Romão, S. Costa, E. Luz, and J. H. Gomes, “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, vol. 10, no. 10, pp. 1–25, 2020, doi: 10.3390/met10101338.
[37] L. Jin-Hee, Bae.Yeong-Do, Park, Mokyoung, “Optimization of Welding Parameters for Resistance Spot Welding of AA3003 to Galvanized DP780 Steel Using Response Surface Methodology,” International Journal of Automotive Technology, vol. 22, no. 3, pp. 585–593, 2021.