Optimization the Resistance Spot Welding Parameters of Austenitic Stainless Steel and Aluminum Alloy Using Design of Experiment Method

Khammass Hussein, Sabah; Sabah Barrak, Osamah

doi:10.30684/etj.34.7A.11

	Optimization the Resistance Spot Welding Parameters of Austenitic Stainless Steel and Aluminum Alloy Using Design of Experiment Method
Engineering and Technology Journal
Article 1, Volume 34, 7A, 2016, Pages 1383-1401 PDF (1.1 M)
DOI: 10.30684/etj.34.7A.11
Authors
Sabah Khammass Hussein; Osamah Sabah Barrak
Abstract
This research aims to study the effect of RSW parameters on the sheerforce of the spot weldedfor two materials {AISI 304L and AA 6061-T6}with (0.5 and 0.7 mm) thickness. Three values for each welding parameters (welding current, electrode force, squeeze time and welding time) are to be used. The effect of those parameters has been analyzed by using design of experiments (DOE) in order to determine and reduce the number of the tested specimens. The experimental tests have been donethat are;shear, micro hardness tests and microstructure examination. It was found that the maximum shear force in welding of similar material AISI 304L is (F = 4.78 KN for t = 0.7 mm), while in the joint of dissimilar material (AA 6061-T6 with AISI 304L), the maximum shear force is (F = 1.42 KN for t = 0.7 mm). These values have been optimized to reach (F =5.13 KN & F =1.54 KN) respectively by using DOE. The minimum shear force was (F = 0.07 KN in t = 0.5 mm). It was found that, increasing the welding current and sheet thickness gave an increase in the shear force, but at the same time the reduction in shear force has occurred during the increasing in electrode force, squeeze time and welding time. From micro hardness tests, it was found that the maximum value of hardness was at the center of nugget zone (NZ) and it reduces slightly until reaching constant values away from nugget zone.
Keywords
Resistance Spot Welding; dissimilar welding; DOE

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