Green manufacturing initiative through the optimization of parameters in resistance spot welding using response surface methodology

Abstract

Welding quality of a product is very important. Resistance Spot Welding (RSW) is a process widely used in the industrial, mostly in the automotive industry. RSW is used to joint two or more materials in order to form the structure of the car. Resistance spot welding requires parameters that play as an important role in the welding process. There are three important parameters in the welding process, namely welding current (kA), welding time (cycle), and electrode force (kN). All three parameters should be optimized in order to produce high quality spot weld joints and less welding defects. In relation to Green Manufacturing, less defects means less waste and less consumption of materials. In the present study, we utilized RSM (Response Surface Method) to optimize the parameters by using statistical and mathematical techniques to analyze the problem. Optimal result parameters on welding current 8.7 kA, welding time 19,25 cycle, and electrode force 1,6 kN with diameter nugget 6,969 mm.