Optimizing Resistance Spot Welding for Enhanced Strength and Nugget Formation: A Taguchi Approach.

Abstract

This manuscript provides a comprehensive analysis of resistance spot welding (RSW), including its technique, empirical research, and findings. The text outlines a comprehensive methodology known as Design of Experiments (DOE) that integrates optimization techniques to study the weld strength and nugget formation of AISI 316L steel grade sheets. The study utilizes many methods including tensile shear testing, destructive weld testing with acid etching, and microstructure analysis using specialized equipment like as the inverted microscope. This study utilized the Taguchi technique and signal-to-noise (S/N) ratio analysis to assess how welding current, pressure and weld time affect the tensile strength and nugget of spot welds. The study's findings demonstrate the optimal setups based on empirical experiments, emphasizing the significant impact of welding current on weld strength. This study thoroughly examines the impact of welding conditions on nugget diameter, tensile-shear strength, and microstructure characteristics such as the fusion zone and heat-affected zone. Studying the microstructure offers valuable insights into how welding factors affect weld properties, including recommendations for ideal welding conditions.