Evaluate Effect of Process Parameters of Resistance Spot Welding on

Mechanical Properties of Inter layered GI Sheet

Submitted By

AVINASH R. PANCHAL
[170030728009]

Guided By
Mr. Manhar S. Kagathara
Assistant Professor
Atmiya Institute of Technology and Science (AITS), Rajkot

A Thesis submitted to

Gujarat Technological University in Partial Fulfillment of the Requirements

for

The Degree of Master of Engineering in

Mechanical (PRODUCTION ENGINEERING)

MAY-2019

ATMIYA INSTITUTE OF TECHNOLOGY AND SCIENCE

“YOGIDHAM GURUKUL”, KALAWAD ROAD, RAJKOT - GUJARAT
 THESIS APPROVAL CERTIFICATE

This is to certify that research work embodied in this dissertation titled “Evaluate Effect of
Process Parameters of Resistance Spot Welding on Mechanical Properties of Inter
layered GI Sheet” was carried out by Avinash R. Panchal (170030728009) at Atmiya
Institute of Technology and Science, Rajkot (003) is approved for the degree of Master of
Engineering with specialization of Production Engineering by Gujarat Technological
University.

Date:

Place:

Examiner’s Sign and Name:

---------------------------------- ----------------------------------
( ) ( )
 ACKNOWLEDGEMENT

This thesis work would not have been possible without the kind support of many people. I
take this opportunity to acknowledge those who have been great sense of support and
inspiration thought out the thesis work. There are lots of people who inspired me and helped,
worked for me in every possible way to provide the details about various related topics
related to my project thus making my dissertation work complete.

My first gratitude goes to our principal Dr. G. D. Acharya and Head of the Mechanical
Department Dr. P. S. Puranik and my Supervisor Assistant Professor of the Mechanical
Department Mr. Manhar. S. Kagathara for their guidance, encouragement and support.
Despite their busy schedule, they are always available to give me advice, support and
guidance during the entire period of dissertation work.

I am very grateful to Shivang S. Jani and Pratik T. Kikani Assistant Professor at

Department of Mechanical Engineering for all their diligence, guidance, encouragement and
help throughout the period of thesis, which has enabled me to complete the thesis work in
time. I also thank them for the time that they spared for me, from their extreme busy
schedule. Their insight and creative ideas are always the inspirational.

I am also thankful to Mr. Kishan Chitroda (Technical Head, R. P. Automotive Industries

Pvt. Ltd.) for providing a platform to carry out my research work at R. P. Automotive
Industries Pvt. Ltd. Last, but not the least my special thanks to our institute, Atmiya
Institute of Technology and Science, for giving me this opportunity to work in a great
environment.

AVINASH R. PANCHAL
ME – PRODUCTION ENGINEERING
(170030728009)
 TABLE OF CONTENTS
Pg. No
Title page I
Certificate ii
Compliance Certificate iii
Thesis Approval Certificate iv
Declaration of Originality v
Acknowledgements vi
Table of Contents vii
List of Figure x
List of Table xii
Abstract xiii

Chapter – 1 Introduction 1
1.1 Background 2
1.2 Resistance spot welding process 5
1.3 Resistance Spot Welding Machine 7
1.4 Resistance Spot Welding Parameters 7
1.4.1 Welding current 7
1.4.2 Welding Time 7
1.4.3 Electrode Force 7
1.4.4 Electrode Material 8
1.4.5 Electrical Resistance 8
1.5 Heat Balance 9
1.6 Resistance Spot Welding Nugget Zones 9
1.7 Industry Profile 10
Chapter – 2 Literature Review 12

2.1 Problem Identification 12

2.2 Literature Review 13
2.3 Research Gap 19
2.4 Objectives 20
2.5 Specification of Welding Machine 20
Chapter – 3 Methodology 23
3.1 Identification of Material 25
3.2 Cut material according to ASME SEC – IX 28
3.3 Pilot Testing 30

Chapter – 4 Design of Experiments 32

4.1 Experimental Design 32
4.2 Taguchi Method 32
4.3 Multi-level Taguchi Design 33
4.4 Experimental Design Combination 36
4.5 Experimental Procedure 37
4.6 Assumptions 37
4.7 Specimen Preparations 38
4.8 Experiments and Testing 38
4.8.1 Performing Experiments 38
4.8.2 Tensile shear test 39
4.8.3 Nugget Diameter Testing 41
4.9 Performing Experiments 42
4.9.1 Tensile shear test And Nugget Diameter result for 42
GI/GI with inter layer of Al.
4.9.2 Tensile shear test And Nugget Diameter result for 43
GI/GI with inter layer of Cu.
4.9.3 Tensile shear test And Nugget Diameter result for 44
GI/GI with inter layer of SS.
Chapter 5 - Result and Discussion 45
5.1 Regression Analysis 45
5.2 Analysis via software 46
5.2.1 Tensile shear test And Nugget Diameter result for 49
GI/GI with inter layer of Al.
5.2.2 Tensile shear test And Nugget Diameter result for 50
GI/GI with inter layer of Cu.
5.2.3 Tensile shear test And Nugget Diameter result for 51
GI/GI with inter layer of SS.
5.3 Analysis of Variance 52
 5.3.1 ANOVA Analysis for Tensile strength And Nugget 53
Diameter
5.3.2 ANOVA Analysis of GI/GI with Al inter layer 54
5.3.3 ANOVA Analysis of GI/GI with Cu inter layer 55
5.3.4 ANOVA Analysis of GI/GI with SS inter layer 57
5.4 Response Surface Optimizer 59
5.5 Result of optimization 60
Chapter - 6 Conclusion and Future Scope 62
6.1 Conclusion 62
6.2 Future Scope 62
References 63
Appendix A: Review Card 66
Appendix B: Compliance Report 72
Appendix C: Paper Publication 73
Appendix D: Standards 74
Appendix E: Plagiarism Report 78
 LIST OF FIGURES

No. Figure Name Pg. No.

Figure 1.1 Manufacturing process boundary conditions 2

Figure 1.2 Resistance spot welding process 3

Figure 1.3 Spot welding cycle 4

Figure 1.4 Resistance Spot Welding Machine (Schematic diagram) 6

Figure 1.5 Different type of Resistance in Spot Welding 8

Figure 1.6 Section view of weld nugget (Schematic Diagram) 9

Figure 1.7 R.P. Automotive Industry 11

Figure 2.1 Testing conditions for test samples 17

Figure 2.2 Tensile-shear strength vs electrode force 18

Figure 2.3 Resistance Spot Welding Machine 20

Figure 3.1 Flow chart of proposed work 24

Figure 3.2 Galvanized iron Test Report 25

Figure 3.3 Aluminum Test Report 26

Figure 3.4 Copper Test Report 27

Figure 3.5 ASME SEC-IX Standard 28

Figure 3.6 1 mm thickness based Galvanized iron sheet (8x4 feet). 28

Figure. 3.7 Cutting GI sheet 29

Figure .3.8 Aluminum inter layer 29

Figure .3.9 Copper inter layer 29

Figure 3.10 SS inter layer 29

Figure 3.11 Pilot Test sample 30

Figure 4.1 Selection of Taguchi Design 33

Figure 4.2 Select number of level and number of factors 33

Figure 4.3 Select 3 level and L9 type design 34

Figure 4.4 Select L9 Runs and 3^3 Columns 34

Figure 4.5 Taguchi design factors value 35
Figure 4.6 Specimen for experiments 38
Figure 4.7 Performing experiments in Industry 39
Figure 4.8 Performing Tensile shear test 40
Figure 4.9 Breaking of Nugget 40
Figure 4.10 Measuring Nugget diamater 41
Figure 5.1 Select analyze Taguchi design 46
Figure 5.2 Analyze Taguchi design menu for tensile strength 47
Figure 5.3 Analyze Taguchi design Options for tensile strength 47
Figure 5.4 Analyze Taguchi design menu for Nugget diameter 48
Figure 5.5 Analyze Taguchi design Options for Nugget diameter 48
Figure 5.6 S/N Ratio of Tensile strength for Al 49
Figure 5.7 S/N Ratio of Nugget Diameter for Al 49
Figure 5.8 S/N Ratio for Tensile strength for Cu 50
Figure 5.9 S/N Ratio for Nugget Diameter Cu 50
Figure 5.10 S/N Ratio for Tensile strength SS 51
Figure 5.11 S/N Ratio for Nugget Diameter SS 51
Figure 5.12 Open ANOVA in Minitab software 53
Figure 5.13 General linear model 53
Figure 5.14 Selection of Response Optimizer 59
Figure 5.15 Optimization plot 60
 LIST OF TABLES

No. Table Name Pg. No.

Table 2.1 Specifications of Resistance Spot Welding Machine 21
Table 3.1 Range of parameter 24
Table 4.1 Experimental Combination 36
Table 4.2 Experimental result GI/GI with inter layer of Al 42
Table 4.3 Experimental result GI/GI with inter layer of Cu 43
Table 4.4 Experimental result GI/GI with inter layer of SS 44
Table 5.1 ANOVA of Tensile strength of Al inter layer 54
Table 5.2 ANOVA of Nugget Diameter of Al inter layer 54
Table 5.3 ANOVA of Tensile strength of Cu inter layer 55
Table 5.4 ANOVA of Nugget Diameter of Cu inter layer 56
Table 5.5 ANOVA of Tensile strength of SS inter layer 57
Table 5.6 ANOVA of Nugget Diameter of SS inter layer 57
Table 5.7 Validation test 61
 Evaluate Effect of Process Parameters of Resistance Spot Welding on
Mechanical Properties of Inter layered GI Sheet

(170030728009)
AVINASH PANCHAL
Atmiya Institute of Technology and Science, Rajkot (003)
Avinashpanchal903@gmail.com

Abstract
Resistance spot welding is a joining technology that continues to be very well-known in a
automotive industries. An additional advantage is that with a proper choice of parameters a
high quality of weld joints can be obtained without being dependent on a welder’s ability. It
is the demand of current automotive industries is to overcome increasing fuel efficiency
requirement. For that aim of industries is component weight reduction in order to improve
performance of Galvanized iron sheet in automotive vehicle. Using interlayer is a promising
approach to overcome this problem. In this study consider effect of different interlayer on
resistance spot welding of galvanized iron sheet. Design of Experiment are used to regulate
proper parameters from the range according to standard. Welding Current, Welding Force
and Welding Time are taken as input parameters, while Tensile shear strength and Nugget
diameter are taken as output parameters. Taguchi method used to generate experimental
design. Effect of interlayer on the failure load is area of interest in this study. Tensile shear
strength and Nugget diameter are measured with testing in laboratory.

Key words: Resistance Spot Welding, Inter layer, Tensile-shear strength, Nugget diameter,
Taguchi method.
 Introduction

CHAPTER – 1

Introduction

1.1 Background:
Manufacturing is the most important thing of any industrialized country. Production staff
in industry must known about the various manufacturing processes used in industry,
materials which is used in industry, also tools and equipments for various manufacturing
parts or items with ideal process plan utilizing appropriate specified safety rules and
precautions to avoid accidents. According to that, every future engineers must idea about
the fundamental requirements of workshop activities in terms of machine, material, money,
technique and other industrial facilities needed to be use properly for plant layout and other
support services effectively adjusted or located in the industry or plant inside an all around
manufacturing organization.

In manufacturing process, the process of putting the parts together to form the product,
which performs the desired function, is called assembly. An assemblage of parts may
require some parts to be joined together using various joining processes. But assembly
should not be confused with the joining process. Most of the products cannot be
manufactured as single unit they are manufactured as different components using one or
more of the above manufacturing processes, and these components are assembled to get the
desired product. Joining processes are widely used in fabrication and assembly work.

Welding is a process for joining two similar or dissimilar metals by fusion. It joins
different metals/alloys, with or without the application of pressure and with or without the
use of filler metal.

Resistance welding is one of the most preferred process by automotive manufacturers. It is

also used by household appliance manufacturers. This process is preferred because it is
cheap, easy and has the ability to be automated easily.

1
 Introduction

Manufacturing process

Casting, Joining, Machining, Metal

forming, Powder metallurgy

Brazing, Soldering, Welding

Resistance,
GTAW,
GMAW,Gas
welding

RSW

Figure 1.1 Manufacturing process boundary conditions

Manufacturing of automotive body is one of the processes in any automotive plant. Mostly
bodies are joined with the help of Resistance Spot Welding (RSW) process. Resistance
Spot Welding is very old, but very efficient process. It is cheap, doesn’t require skilled
labour and can be easily automated.

1.2 Resistance spot welding process:

Resistance Spot Welding comes under the category of fusion welding process. Fusion
welding process includes processes, where welding (joining) of two or more parts happen
by melting the parent metals.

In some welding processes, like Gas-Metal Arc Welding (GMAW) and Gas Tungsten Arc
Welding (GTAW), a filler metal is used and that metal joins the metal parts by first
melting and then solidifying in between the parts. Resistance Spot Welding is different as
fusion welding process.

2
 Introduction

Figure 1.1 gives an overview of how the Resistance Spot Welding works. Sheet metals to
be joined are put between the electrodes. Force is applied through the electrodes. Current
of an amount (in kA) is passed through the plates. An appropriate time either in AC cycles
or in seconds is selected, for which the current will be passed through both the sheets. A
joint called nugget is appeared after the process ends. Both sheets are joined through
nugget.

Figure 1.2 Resistance spot welding process[33]

In resistance welding processes no fluxes are employed, the filler metal is rarely used and
the joints are usually of the lap type. Its equation is given below:

H = I. V. t

= I. (IR). t

= I2. R. t

Where, H = Total Heat generated (Joule)

I = Welding Current (Ampere)

R = Total Resistance (Ohms)

t = Total Welding time (seconds)

3
 Introduction

Entire Spot Welding Process gets completed within five time duration:

1. Squeeze Time
2. Weld Time
3. Post-heat time
4. Cooling time
5. Off time

Figure 1.3 Spot welding cycle[34]

Squeeze Time:

Electrodes put up pressure on the sheet stacks. No welding current is applied. Normally,
10-20 AC Cycles are applied for squeeze time. Once force is applied through electrodes,
the sheet stack has vibrations and oscillations. If immediately current is applied, then
weld location will get deteriorated. That’s why, squeeze time is applied to nullify the
oscillations in sheet stacks.

Pre-heat Time (Optional):

Pre-heat time applies the current of low intensity. This helps in reducing thermal gradients
in metal sheet stacks.

4
 Introduction

Weld Time:

Current is applied for a certain time duration according to sheet thickness and material
properties. Due to joule heating, welding nugget is generated by melting the metal stacks.

Post-heat Time (Optional):

This time is not applied mostly as spot welding is focused on joint strength. However, in
case of carbon alloys, if grain refinement is required, then post-heat time is required.
Current of low intensity is applied in this time duration.

Hold Time:

This time is required as welding nugget should be allowed to solidify in the region. Heat is
taken away mostly by electrodes, which are either water cooled or air cooled. If not
applied, nugget will become brittle. If applied for longer times, electrodes will get
deteriorated due to heat.

Off Time:

It is defined as the time duration between beginning of squeeze time for the next weld and
end of hold time. This time is required to reposition electrodes and remove any deposition
either on the sheet or electrodes.

1.3 Resistance Spot Welding Machine:

In the figure, construction of a resistance spot welding machine is shown. While the
process is complex, construction is very simple. Two electrodes are fixed in the machine.
Upper electrode is movable, while lower electrode is stable. Current is passed through the
upper electrode to lower electrode through the sheet metal components put in between the
electrodes. Electrodes are made of copper-alloy. Most electrodes are made as per ISO
(International Standardization Organization) or RWMA (Resistance Welding
Manufacturer’s Association) standards.

Resistance Spot Welding Machine has the ability of welding the sheets up to 6 mm as total
thickness. It can weld the sheets of different materials, given that the sheet material has
bulk electrical resistance higher than that of the electrode material.

5
 Introduction

An A.C. power supply is given to the machine. Machine has an A.C. step-down
transformer. It increases the current to the level of Kilo-Ampere (KA). If the machine is
D.C., then it also includes a rectifier, which converts an A.C. power supply to a D.C.
power supply. Current then passes through the electrodes and welding happens.

Water lines are provided in the machine. Water is circulated at a fixed rate through the
electrodes to cool the electrodes during welding process.
Pressure gauge is provided in the machine to adjust the electrode pressure. The electrode
force is one of the main parameters, which can be adjusted through the pressure gauge.

Figure 1.4 Resistance Spot Welding Machine (Schematic diagram)[35]

6
 Introduction

1.4 Resistance Spot Welding Parameters:

According to ASME Section IX, there are mainly two types of parameters:

1. Essential Parameters.

2. Nonessential Parameters.

Essential Parameters are those, which can alter mechanical properties, if changed. Essential
Parameters, if changed, need requalification of Welding Procedure Specification (WPS).
Nonessential Parameters are those, which do not require requalification of WPS, if
changed.

1.4.1 Welding current:

Welding Current is the most important Parameter. It comes under the category of Essential
Parameters. Welding current passes through sheets, making joule heating possible. Due to
this joule heating, nugget starts to form.

Due to phenomena of contact resistance between plates, which is much higher than bulk
resistance, nugget starts to form at the point of contact between both the sheets. Both
sheets melt and gets joined.

Welding current should be put in a limit. Excessive welding current often results in
sputtering of sheet called expulsion. Welding current under the certain limit would not be
able to form the nugget and welding would not be possible. Also for mechanical strength,
it would be good to have higher welding current as much as possible but within the range.

1.4.2 Welding Time:

Welding time comes under the category of essential parameters. It can be set as an AC
cycle or seconds. Welding time decides, for how much time welding current should be
passed.

Welding time affects the mechanical properties. If welding time is higher, then there will
be excessive burning of nugget.

1.4.3 Electrode Force:

Electrode Force is one of the essential parameters. It minimizes the shunting effect. Due to

7
 Introduction

electrode force, welding current passes through a small area and heat generated can be
constricted to a small, finite area.

1.4.4 Electrode Material:

Electrode are of numerous kinds. Predominantly truncated cone type terminal is utilized.
Electrode are primarily made of Copper alloys. Electrode are of RWMA (Resistance
Welding Manufacturer's Association) standard, which are from class-1 to class-12 as per
their diameter across.

1.4.5 Electrical Resistance:

The electrical resistance in resistance spot welding, which is make the resistance spot
welding possible in five different types:

1. Contact resistance between upper electrode and upper sheet (R1)

2. Bulk resistance of upper sheet (R2)
3. Contact resistance of both sheets at faying surfaces (R3)
4. Bulk resistance of lower sheet (R4)
5. Contact resistance between lower electrode and lower sheet (R5)

Figure 1.5 Different type of Resistance in Spot Welding[17]

From the experiments, it is INFERRED that the contact resistance between two sheets at
faying surface (R3) has the highest resistance. That is because nugget formation starts from
the faying surfaces.

8
 Introduction

1.5 Heat Balance:

Heat balance is significant wonders. Despite the fact that it is a perfect case, it is taken as
an ideal condition for spot welding. In Heat balance, it is accepted that, both the sheets
have same temperature and have same electrode force. Likewise, it is accepted that, the
geometric community for nugget to begin forming is equivalent to geometric place for both
the joint in both the sheets. Likewise, it is expected that, both the sheets have same
measure of nugget and both the sheets have practically same temperature amid nugget
formation, spreading and solidification.

1.6 Resistance Spot Welding Nugget Zones:

In Resistance Spot Welding, the welding nugget can be characterized into three zones as
below:
• Fusion Zone (FZ)
• Heat Affected Zone (HAZ)
• Base-Metal (BM)
As appeared in figure, fusion zone is the primary area where nugget is formed. During the
welding fusion zone in highest temperature is available. In the fusion zone metals get
melted and then solidified. Heat affected zone (HAZ) is shaped close to the fusion zone. It
is formed when heat is spread close to the fusion zone. As indicated by temperature
distribution likewise, it has two unique zones-upper-basic and sub-basic. At long last,
Base-Metal or BM is the unaffected metal from spot welding. Heat was not ready to scatter
in the base metal.

Figure 1.6 Section view of weld nugget (Schematic Diagram)[19]

9
 Introduction

1.7 Industry Profile:

Industry, in which, I was allowed to work is R. P. Auto Industries. Industry is situated in

Shapar, Gondal Road, Rajkot.

Industry has gained expertise in making sheet metal components for automotive body.
Industry was started in year 1994; in attika industrial area, situated inside Rajkot city. It
transferred it’s manufacturing unit form attika to shaper in year 2000.

Industry in testing facilities are also available. Annual Turnover of industry is Rs.50 Lakh
– 1 Crore.

Products being manufactured in the plant are:

• Automobile body for Piaggio Ape mini-truck

• Body for captain tractor (Captain is a local mini-tractor manufacturer in Rajkot.)
• Body parts for rickshaws
• Circuit supporter panel in Alternator

Processes being performed in R. P. Auto Industries:

• Resistance Spot Welding

• Gas-Metal Arc Welding
• Grinding
• Metal Forming
• Plasma Cutting
• Laser Cutting

10
 Introduction

Figure 1.7 R.P. Automotive Industry

11
 Literature Review

CHAPTER – 2

Literature Review

2.1 Problem Identification:

Resistance spot welding process is a boon for automotive industries, there are
approximately 5000 spot welds in every car, susceptible to various loading conditions. It is
the need of current automotive industries towards economical fabrication with improved
mechanical properties of Galvanized Iron Sheet.

The Automotive industry is constantly attempting to improve efficiency of fuel

consumption by utilizing lightweight materials, for example, Galvanized iron, Aluminum
and Magnesium alloy.

Just suggesting correct parameter range, which is given in many standards doesn’t do the
job totally. Industry needs justification. It comes with experiments and testing. Also the
quality that industry wants is not the same as in standards.

Presently, the most encouraging way to deal with take care of this issue is utilizing
interlayers which can improve microstructure and mechanical properties of Galvanized
iron welds.

12
 Literature Review

2.2 Literature Review:

M. Sun et al. [1] studied the dissimilar joining of aluminum and magnesium alloys with
nickel interlayer for prevents the formation of Al-Mg. in this paper microstructure
investigation via EDS/SEM and XRD methods. Also increasing current the nugget
diameter strength is good. Also its prevent formation of the Al-Mg intermetallic
compounds.

H.C.Lin et al. [2] carried out resistance spot welding in effect of zinc layer on galvanized
mild steel. Welding input parameter taken as welding current and welding time and for the
output parameter considered tensile test. Thickness of galvanized sample is 1.2 mm and the
optimum time is 16 cycles. Two step resistance spot welding nugget is larger then the first
step.

Jian chen et al [3] investigate multi scale FE modeling approach for fracture behavior of

Al-Steel resistance spot welding. Thickness of IMC layer is less then 10μm. According to

result, we will say that strength is depends on IMC layer, which is change with joint
interface. Effective shear strength and tensile strength of IMC layer predicted in micro
scale models.

Ihsan Kadhom Abbas Al Naimi et al [4] studied the weldability of new material
sandwich for automotive application and research that the weldability could be optimum
with using two pulses and optimized its welding parameters. Also carried the tensile shear
strength for output parameters and after that getting optimum input parameter is 3.5 kN,
5.5 kA, 8 cycles.

Fatih Hayat et al [5] carried out increasing welding current nugget diameter is increased.
And nugget diameter of Al alloy has lower tensile strength and hardness in ratio of Mg% is
high currents and Al% has low current. Increasing in welding area current is also
increased.

I.H. Hwang et al [6] studied we attempted to join steel to Al-Mg combination utilizing an
obstruction spot welding technique, the impact of Mg content in Al compound on the joint
quality and the interface on the joint strength utilizing an addition metal of economically

13
 Literature Review

Al containing little Mg effectively improved the quality of the SS400/Al-Mg compound

joint and the fractured happened in Al-Mg combination base metal.

H. Oikawa et al [7] Invstigate Deformation of IMC layers did not exist at the interfaces of
the aluminum clad steel sheets utilized as addition metals and the strip quality at the
steel/aluminum interfaces demonstrates a high estimation of over 32·1 N mm−1.The
resistance spot welding current range for spot welding of steel sheet to aluminum sheet lay
halfway between those for steel sheet to steel sheet and aluminum sheet to aluminum sheet
welding. The fatigue quality of steel sheet to aluminum sheet joints created utilizing embed
metals was to some degree lower than that of aluminum sheet to aluminum sheet joints.
This is brought about by the off set eff ect of the interlayered metals.

Ranfeng Qiu et al [8] carried out from this paper is In the resistance spot welding of
stainless steel/aluminum, higher temperature can be gotten in comparison with ordinary
one. The outcome reveals that the utilizing of cover plate is useful to improve resistance
spot welding temperature field.

Manoj Raut et al [9] studied electrode force, welding current, welding time consider as a
input parameters for experiments and tensile shear strength consider as a output parameter.
The welding parameters are the significant for the quality of the welded joint. which may
increment or reduction the strength of the welding joint so we can say that the combination
of the appropriate parameters is vital for the most extreme strength of the resistance spot
welded joint.

Alaa Muhsin Saeed et al [10] studied in this paper the effect of welding parameters on the
weldability with titanium and nickel inter layer. The shear strength and microstructural of
the experimental study is welding current has important influence on the strength. And the
range of current for this study is 2.5 – 4.0 kA. Also weld nugget is undoubtedly improved
the strength spot joint.

J. Sagues Tanco et al [11] carried out experiments perform on new light weight sandwich
material by resistance spot welding and analyzed by numerical simulations. A procedure
window near 2.5 kA at procedure times extending from 8 cycles (160 ms) to 20 cycles

14
 Literature Review

(400 ms) was discovered, which is acceptable for industrial assembly lines, where a require
a
process window of around 2 kA is basic for standard resistance spot welding in the
automotive industry.

M. C. Katharotia et al [12] studied the effect of welding current, welding cycle, electrode
pressure in resistance spot welding of dissimilar automobile steel (DP 600 with AISI 304)
Taguchi method was utilized to know about multivariable nature and its impact in
characterizing a resistance spot welding. Tensile shear strength for Austenitic stainless
steel AISI 304L and DP 600 was observed to be relatively more than that of for
comparable sheets ( AISI 304L to AISI 304L and DP 600 to DP 600). Also from the result
we can that welding current is the most important parameter of welding strength.

Prashantkumar V K et al [13] investigate study on the Resistance Spot Welding of Cold-

Rolled Closed Annealed steel sheet. The thickness of sheet was 2 mm of each specimen.
The creator began with arbitrary parameters and took the reference of heat produced.
Creators took the range from flap tests. Creators took plan of experiments technique and
utilized full-factorial method. And programming SYSWELD was utilized to check the
outcomes with the help of temperature and nugget diameter.

S. Aslanlar et al. [14] carried out from this paper welding time impacts on Automotive
sheets. The creator took chromate alloyed steels having 1.2 mm thickness. And tensile
shear strength and Tensile-peel quality were taken as output parameter. Also having
Electrode Force as consistent parameter, creator changed the welding time and
concentrated its impact on the output parameter.

Hakan Aydin et al [15] studied was investigate to research the mechanical properties and
the microstructure of dissimilar resuitance spot welds between steel sheets of DP600 and
DP1000 utilizing to change in welding current for automobile use. Also increasing welding
current, first, the NS expanded straightly, second, the widths of the HAZs on the two sides
decreased, third, the PAGs in the HAZs ended up coarser and, fourth, up to 10 kA, the
columnar grains in the FZ were refined.

Milan Brozek et al [16] carried out from this work resistance spot welding test from two

15
 Literature Review

sheet of same and different thickness. Size of specimen is 100 x 25 mm and material is low
carbon steel. Also taken thickness is 0.8+0.8, 1.5+1.5, & 3.0+3.0 and changing in input
Parameter. And. The compressive force was chosen according to the welded sheets
thickness from 0.8 to 2.4 kN. it is conceivable to increase the spot weld break power at
sheets of thickness 0.8 + 0.8 mm of around 11 %, at sheets of thickness 1.5 + 1.5 mm of
around 21 %, at sheets of thickness 3.0 + 3.0 mm of around 4 %, at sheets of thickness 0.8
+ 1.5 mm of around 18 %, at sheets of thickness 0.8 + 3.0 mm of around 7 % and at sheets
of thickness 1.5 + 3.0 mm of around 3 % contrasted with welds made utilizing the welding
factors as indicated by the producer.

Aravinthan Arumugam et al [17] in this study the created controller had the capacity to
control the electrode force during welding to pursue the given force profiles. Decreasing
the electrode force during welding encourages the inception of resistance spot weld
development prior in the weld cycle which in creates greater weld diameter and weld
strength. electrode force as a control parameter.

A. Ambroziak et Al [18] carried out from this study the aluminum alloys are all the more
habitually utilized in car industry particularly as an elective material for vehicle bodies.
The most well known technique for joining body sheets is resistance spot welding.
Aluminum and its alloys can be associated by this technique. It requires high power
welding current and time.

Seyedeh Nooshin Mortazavi et al [19] investigate relationship between welding current

and mechanical properties of the dissimilar material aluminum alloy and low carbon steel
by resistance spot welding. Formation of weak intermetallic in sheet/sheet interface
disintegrated weld properties. The specimen which was welded at the weld current of
12.5 kA showed great mechanical properties, for example, high load and also cracked in
failure mode.

X. Sun et al [20] investigate whether resistance spot welding between steel and
aluminum can be getting by using with inter layer material. It was discovered that two
particular fusion zones formed amid the resistance spot welding procedure of aluminum
to steel utilizing a progress aluminum-clad steel strip. The nugget on the steel side is a
standard, elliptical weld with dendritic grain structure inside the piece area.

16
 Literature Review

L. LIU et al [21] Studied of magnesium to steel joint strength with effects of surface
condition and welding parameters. the systems of joint arrangement and the eff ects of the
Zn soldering layer on the weld strength. A correlation of Mg/steel with Zn-covered
steel/Zn-covered steel, Au-plated-Ni, and barc Ni/barc Ni are discussed. A conceivable
development of this innovation additionally is discussed.

Kenji Miyamoto et al [22] in this investigation concerns a dissimialr materials joining

procedure for aluminum (Al) alloy and steel to reduce the vehicle body weight. It was
demonstrated that the welded joints acquired with this joining method can fulfill every one
of the necessities for application to the vehicle body, fatigue properties, low-and high-
temperature tensile properties.

Ranfeng Qiu et al [23] studied in the resistance spot welding of staineless steel/aluminum
alloy, higher temperature can be gotten in comparison with conventional one. The outcome
utilizing of cover plate is useful to improve resistance spot welding temperature field. the
thickness of the response layer was slight at the peripheral area and it increase as center of
the weld.

Figure 2.1 Testing conditions for test samples [24]

Han et al. [24] carried out resistance spot weld quality for tensile shear and cross-tension

17
 Literature Review

strength in aluminum AA5753. Author arrived at a solution that, the load conveying limit
with regards to cross-tension weldments are most elevated by tensile shear strength and
coach peel strength.

M. Pouranvari et al. [25] Studied gave a critical review of resistance spot welding for
automotive sheets. Authors included AHSS, DP, mild-steel etc as the material. Welding
current, welding time, electrode force, hold time, squeeze time, tensile-shear strength,
cross-tension strength, microstructure and hardness are considered. Author gave
explanation of analytical methods and gave empirical relations used for various

parameters.
Figure 2.2 Tensile-shear strength vs electrode force [26]

H. Sun et al. [26] studied the effect of electrode force on the tensile-shear strength using
low-carbon steel sheets. Tensile-shear strength increases as electrode force increases. If the
variable electrode force is there, then it deteriorates the weld quality. Also, low electrode
force leads to expulsion in the weld.

Wei Liu et al. [27] investigate took only sheet thickness as the only input parameter.

18
 Literature Review

Tensile-shear strength, Fatigue strength and nugget diameter were taken as input
parameters. Material taken was cold-rolled low carbon steel sheet and austenitic steel
sheet. It was found that an intermetallic layer was found in between the steels, even if
welding was done in identical sheet thickness and identical welding parameters. This
intermetallic layer decreases the fatigue strength and tensile-shear strength of welding
nugget.
V. Onar et al. [28] studied the effect on welding time on hardness using TRIP and
DP600 steel. Welding time, electrode force and welding current were taken as the input
parameters. Tensile-shear and tensile-peel strength were taken as output parameters. It
was found that, for both steels, welding time has more effect on tensile-shear and tensile-
peel strengths. Also, it has more effect on weld nugget. Welding current has more effect
on hardness

Lin et al. [29] studied the optimization of the resistance spot welding process using
taguchi method and artificial neural network. Taguchi method was used when one has
fewer experiments to do. Also, neural network was used to predict the output parameter.
Low
carbon steel was used as material. Neural network is an n-order regression, which can
predict output parameters according to regression formulas from the input parameter and
taguchi experimental design. Input parameters were taken as welding current and welding
time. Output parameters were taken as tensile-shear strength and nugget diameter.

Xiaodong Wang et al. [30] investigate the effects of resistance spot welding electrode
force on metal. Authors used DP600 (Dual Phase) steel as the material. The current and
time were varied. For different temperature, stresses in the nugget and nugget boundary
were observed. During the welding process, the stress at the boundary were higher than at
the centre of the nugget. The forces come near to original values after the welding process
was completed. For numerical simulation, a Finite Element Analysis package SORPAS
was used.

19
 Literature Review

2.3 Research Gap:

Technology of producing high strength GI/GI Resistance Spot Welding has not been
developed yet. Use an interlayer is the most promising approach in welding of GI to GI.
However, there is a least of literature on Resistance Spot Welding of GI to GI with
different interlayers. Understanding the metallurgical aspects of welding GI to GI with
different interlayers is essential in order to promote utilization of these alloys in the
automotive industry.

2.4 Objectives:

➢ To identify the process parameters affecting resistance spot welding for sandwich
material.
➢ To investigate the optimum process parameter range for sandwich material to
improve mechanical properties.
➢ Investigate the role of different interlayers on the microstructure and mechanical
properties of GI resistance spot welds.
➢ To compare the quality of weld for sandwich material.

2.5 Specification of Welding Machine:

Resistance spot welding machine to be used is manufactured by Kriton Manufacturers Pvt.

Ltd. Machine has the capacity of 20 KWh. It is pedal operated pneumatic type resistance
spot welding machine. Machine was made by RWMA (Resistance Welding
Manufacturer’s Association) handbook specifications.

20
 Literature Review

Figure 2.3 Resistance Spot Welding Machine

Table 2.1 Specifications of Resistance Spot Welding Machine

Term Value
Power at 50% duty cycle 20 KWh
Maximum current 11000 Amperes
Maximum time 99 AC Cycles
Maximum pressure available 10 bar
Electrode diameter 20 mm
Pneumatic cylinder Specifications As per IS: 14555
Maximum thickness to be welded 6 mm
Cooling medium Water

Water flow through electrodes 5 liter/min

Controls Analog Panel
Transformer type According to RWMA
Electrode material Copper Alloy
Electrode Shape RWMA Class 2
Phase 11 + N
Input voltage 415 Volts
Pneumatic cylinder stroke 75 mm
Maximum stroke of electrodes 30 cm
Electrode Type Consumable

21
 Methodology

CHAPTER – 3

Methodology

The following is the methodology followed during the entire project study:

❖ Perform pilot tests for checking the feasibility of the proposed tool material.
❖ Selection of input and output process parameters for optimization.
❖ Creating Design of Experiments (DOE) using 3*3 Taguchi method.
❖ Carry out experiments using the selected values of input parameters.
❖ Inspection and testing of experimental samples for lap shear tensile strength and
Nugget diameter.
❖ Generate mathematical equations by regression analysis of the Taguchi model
Created earlier.
❖ Optimize the input parameters and compute the values of output parameters for the
Same.
❖ Carry out sample weld using the optimized input parameters and test it for strength
And Nugget diameter.
❖ Compare and validate results.
❖ Identification of sheet material type and grade by Optical Emission Spectrometry.

The adjacent figure shows the flow chart of the entire work to be done during the entire
dissertation study.

23
 Methodology

Identification of material grade

Pilot testing

Cut Material According to ASME - SEC- IX Standard

DOE using Taguchi method

Experiments using selected parameters

Testing of specimen for Srength and Nugget diameter

Generate mathematical model

Computation of output parameters using optimized

input parameters

Testing of sample welded using optimized parameters

Compare and validate results.

Figure 3.1 Flow chart of proposed work

24
 Methodology

3.1 Identification of Material

The identification of the base material galvanized iron was important in order to
know the chemical composition and mechanical properties. The certificate or test
report has been given below. The test was done by YOR LAB Service at 150 Feet
Ring Road, Opp. Gondal Bypass BRTS Bus Stop, Rajkot. The Material is
Galvanized iron.

Figure 3.2 Galvanized iron Test Report

25
 Methodology

The identification of the material for inter layer Aluminum was important in order
to know the chemical composition and mechanical properties. The certificate or
test report has been given below. The test was done by YOR LAB Service at 150
Feet Ring Road, Opp. Gondal Bypass BRTS Bus Stop, Rajkot. The Material is
Aluminum A1070.

Figure 3.3 Aluminum Test Report

26
 Methodology

The identification of the material for inter layer Copper was important in order to
know the chemical composition and mechanical properties. The certificate or test
report has been given below. The test was done by YOR LAB Service at 150 Feet
Ring Road, Opp. Gondal Bypass BRTS Bus Stop, Rajkot. The Material is Copper
C83400.

Figure 3.4 Copper Test Report

27
 Methodology

3.2 Cut material according to ASME SEC – IX

Figure 3.5 ASME SEC-IX Standard [33]

Figure 3.6 1 mm thickness based Galvanized iron sheet (8x4 feet).

28
 Methodology

Cutting GI sheet Length of specimen (L) is 101.6 mm And width (W) 25.4 mm.

Figure. 3.7 Cutting GI sheet

Aluminum inter layer Copper Inter layer Stainless steel Inter layer
(25.4 mm) (25.4 mm) (25.4 mm)

Fig.3.8 Aluminum inter layer Fig.3.9 Copper inter layer Fig.3.10 SS inter layer

29
 Methodology

3.3 Pilot Testing:

The pilot test of proposed method has been carried out on galvanized iron sheet with
different
Inter layer like, Aluminum, copper and stainless steel at R. P. Automotive Industry PVT
LTD, Rajkot. The figure of Successful weld joint has been shown below:

Figure:3.11 Pilot Test sample

30
 Methodology

Range find out from the pilot experiments are as follows:

Table 3.1 Range of parameter
Range
Parameter Low High
Welding current (kA) 8.250 10.450
Welding Time 7 9
(Cycle)
Electrode Force (kN) 4.2 5.0

31
 Design of Experiments

CHAPTER – 4

Design of Experiments

4.1 Experimental Design:

Design of Experiments (DOE) or Experimental Design is a procedure under SPC
(Statistical Process Control). In this procedure, different experimental design are utilized.
These experimental design are demonstrated mathematically. There are mainly three type
of experimental design.

a) Full-factorial Method

b) Response Surface Method

c) Taguchi Method

4.2 Taguchi Method:

This technique of design of experiments including different factors was first created by
Englishman, Sir R. A. Fisher. The technique is commonly known as the factorial design of
experiments.

A full factorial design will recognize every conceivable combination for a given set of
factors. All the industrial experiments comprise noteworthy number of factors. A full
factorial design results in a large number of experiments.

To reduce the number of experiment, a small set from all the possibility is chosen. The
technique of choosing a limited number of experiments which delivers the most
information is known as a partial fraction experiment.

Taguchi Method is most preferred method, if one needs to do less amount of experiments.
Taguchi method gives the least experimental combinations among all.

32
 Design of Experiments
4.3 Multi-level Taguchi Design:
For the experimental design, statistical analysis software Minitab version 17.0 was used. In
this software, as the photographs shows, Taguchi Method was selected from ‘stat’ option.

Figure 4.1 Selection of Taguchi Design

After selection of Create Taguchi Design, a menu will be popped-up which will ask for
number of level Design. By default, type of are 2. Select number of level as 3. Also select
number of factors are 3. And then click on ‘OK’ button. It is shown in figure.

Figure 4.2 Select number of level and number of factors

33
 Design of Experiments
Then go in ‘Display available Design’ and select 3 Level in L9 type deign and then go on
OK button.

Figure 4.3 Select 3 level and L9 type design

Then double click on ‘design’ option and select L9 runs (3^3 columns and click on OK
button.

Figure 4.4 Select L9 Runs and 3^3 Columns.

34
 Design of Experiments
And go to ‘Factor’ option and click OK and put value of input parameters and then click
OK button.

Figure 4.5 Taguchi design factors value

Clicking on OK button for factors and then clicking on OK button for the main window,
gives one experimental design combinations.

35
 Design of Experiments
4.4 Experimental Design Combination:

After giving Input values in the software windows, experimental design combinations as
per run order are given below:

Table 4.1 Experimental Combination

Run Welding Welding Electrode

Orde Current Time Force
r

1 8.25 7 4.2

2 8.25 8 4.6

3 8.25 9 5.0

4 9.35 7 4.6

5 9.35 8 5.0

6 9.35 9 4.2

7 10.45 7 5.0

8 10.45 8 4.2

9 10.45 9 4.6

Notice that, it is the experimental combination of all inter layer like, GI based SS304 inter
layer, GI based Aluminum A1070 inter layer and GI based Copper C83400 inter layer.

So, Total number of 27 experiments are performed in industry.

36
 Design of Experiments

4.5 Experimental Procedure:

After preparing for the experimental design combinations, experimental work is done.
This includes:

• Assumptions
• Preparation of specimens
• Preparing the machine
• Performing experiments according to run order
• Testing specimen according to output parameters

4.6 Assumptions:

Before preparing the specimens and performing the experiments, we are going to
assume some things for ease of experimentation and analysis:
✓ Both the electrodes are perfectly aligned
✓ Both the electrodes have no defect in passing of current
✓ Electrodes are perfect in shape
✓ Work conditions in the industry are ideal
✓ Welding machine performs as per settings
✓ The plates to be welded have homogeneous properties
✓ Electrodes are perfectly cooled
✓ Worker has enough skills for operating the machine
✓ There is no defect in the material of sheet.

37
 Design of Experiments

4.7 Specimen Preparations:

Specimens are 1 mm sheet of Galvanized iron sheet which will be used as base sheet
for experiments. And other material like, Stainless steel, Aluminum, & Copper are
using as inter layer material.

Size of the specimen is taken as per ASME SEC-IX.

Figure 4.6 Specimen for experiments

4.8 Experiments and Testing:

4.8.1 Performing Experiments:

Experiments are performed in the industry. First, the sheets are cut as per dimensions of
the specimen. Then, on the welding machine, the specimens are experimented as per the
design of experiments block.

38
 Design of Experiments

Figure 4.7 Performing experiments in Industry

4.8.2. Tensile shear test:

Tensile-shear test is one of the most important parameter in determining the strength of
the welding nugget. For this reason, tensile-shear test is performed on the specimen.

Tensile-shear tests are performed to know the performance of the sheet and Gives
strength of welds.

The most common testing machine used in tensile testing is the Universal Testing
Machine his type of machine has two crossheads; one is adjusted for the length of the
specimen and the other is driven to apply tension to the test specimen.

39
 Design of Experiments

Figure 4.8. Performing Tensile shear test

Figure 4.9 Breaking of Nugget

40
 Design of Experiments

4.8.3 Nugget Diameter Testing:

Nugget diameter was measured with the help of digital Vernier caliper. least count of a
measuring instrument is the smallest change in the measured quantity that can be resolved
on the instrument's scale. A Vernier Caliper have a least count of 0.1 mm.

Figure 4.10 Measuring Nugget diamater.

41
 Design of Experiments

4.9 Experimental Results:

4.9.1 Tensile shear test And Nugget Diameter result for GI/GI with inter layer of Al.

Table 4.2 Experimental result GI/GI with inter layer of Al

Run Welding Welding Weldin Breaking Nugget

order current time g force load Diamet
(kA) (Cycles) (kN) (kN) er
(mm)

1 8.250 7 4.2 2.36 5.86

2 8.250 8 4.6 2.28 5.78

3 8.250 9 5.0 2.11 5.94

4 9.350 7 4.6 2.45 4.27

5 9.350 8 5.0 2.16 4.75

6 9.350 9 4.2 3.44 5.53

7 10.450 7 5.0 3.15 5.41

8 10.450 8 4.2 3.28 5.77

9 10.450 9 4.6 4.24 6.03

42
 Design of Experiments

4.9.2 Tensile shear test And Nugget Diameter result for GI/GI with inter layer of Cu.

Table 4.3 Experimental result GI/GI with inter layer of Cu

Run Welding Weldin Weldin Breaking Nugget

order current g time g force load Diamet
(kA) (Cycles) (kN) (kN) er
(mm)

1 8.250 7 4.2 1.11 5.03

2 8.250 8 4.6 0.93 4.93

3 8.250 9 5.0 2.22 5.78

4 9.350 7 4.6 1.22 5.59

5 9.350 8 5.0 1.46 5.67

6 9.350 9 4.2 1.80 5.88

7 10.450 7 5.0 2.12 5.6

8 10.450 8 4.2 0.9 4.12

9 10.450 9 4.6 2.98 5.97

43
 Design of Experiments

4.9.3 Tensile shear test And Nugget Diameter result for GI/GI with inter layer of SS.

Table 4.4 Experimental result GI/GI with inter layer of SS

Run Welding Weldin Weldin Breaking Nugget

order current g time g force load Diamet
(kA) (Cycles) (kN) (kN) er
(mm)

1 8.250 7 4.2 3.76 4.78

2 8.250 8 4.6 4.30 4.59

3 8.250 9 5.0 3.94 5.61

4 9.350 7 4.6 3.33 4.89

5 9.350 8 5.0 3.64 5.81

6 9.350 9 4.2 4.44 6.09

7 10.450 7 5.0 2.76 4.87

8 10.450 8 4.2 3.62 5.82

9 10.450 9 4.6 4.08 5.68

44
 Result and Discussion

CHAPTER 5

Result and Discussion

5.1 Regression Analysis:

The main objective of regression analysis is to make an equation based on statistical

techniques, which can predict the behaviour of a particular system or output. It takes in
observation or experimental values and then makes a mathematical equation based on
the inputs given.

Regression has two main types based on relation:

-Linear Regression

-Non-linear Regression

Linear regression gives you linear relationship between output variable and input
variable. Linear regression may have non-linear terms, but it has only linear
relationship. Non-linear regression analysis is literally non-linear. It gives the
relationship in terms of exponential, quadratic, logarithmic etc. terms.

In linear regression analysis, there may be one or more output parameters. Based on
number of input parameters, there are mainly two types:

- Simple-linear Regression

-Multiple-linear Regression

If there is only one input variable, then it is called as single regression. If there are more
than one input variables, then it is called as multiple regression.

45
 Result and Discussion

A simple regression formula is shown below:

Y = α + β.x (n) + ε…………………………………………………………………(5.1)

Where, Y = Output Parameter

α = Constant Coefficient or intercept

β = Coefficient of input variable or slope

ε = Error or non-measurable variables, which can’t be included in

model n = nth variable

5.2 Analysis via software:

For the analysis of results via regression, again the minitab software was used.

Figure 5.1 Select analyze Taguchi design

46
 Result and Discussion

Figure 5.2 Analyze Taguchi design menu for tensile strength

After selecting the option, a new menu will open. Select Tensile strength as
output.

The output will be a table with parameters and regression equation, value or R-square,
R-prediction and R-adj.

Figure 5.3 Analyze Taguchi design Options for tensile strength

For Tensile strength Signal to Noise Ratio in select “Larger is Better” option because it
will be gives best output for the result.

47
 Result and Discussion

Figure 5.4 Analyze Taguchi design menu for Nugget diamater

After selecting the option, a new menu will open. Select Nugget Diameter as
output.

Figure 5.5 Analyze Taguchi design Options for Nugget diameter

For Nugget diameter Signal to Noise Ratio in select “Nominal is best” option because it
will be gives best output for the result.

48
 Result and Discussion

5.2.1 Tensile shear test And Nugget Diameter result for GI/GI with inter layer of Al.

Figure 5.6 S/N Ratio of Tensile strength for Al

Figure 5.7 S/N Ratio of Nugget Diameter for Al

The goal of this investigation was to maximize the Tensile strength and optimum the
nugget diameter. Thus larger is better for and nominal is best was applied to Tensile
strength and nugget diameter respectively. From the Signal to Noise Ratio graph through
we can say that Welding time is more effect on output for GI/GI with Al inter layer.

49
 Result and Discussion

5.2.2 Tensile shear test And Nugget Diameter result for GI/GI with inter layer of Cu.

Figure 5.8 S/N Ratio for Tensile strength Cu

Figure 5.9 S/N Ratio for Nugget Diameter Cu

From the Signal to Noise Ratio graph through we can say that Welding time is more effect
on output for GI/GI with Cu inter layer.

50
 Result and Discussion

5.2.3 Tensile shear test And Nugget Diameter result for GI/GI with inter layer of SS.

Figure 5.10 S/N Ratio for Tensile strength SS

Figure 5.11 S/N Ratio for Nugget Diameter SS

From the Signal to Noise Ratio analysis through we can say that for getting best output for
tensile strength we select larger is better and for optimum nugget diameter we select
nominal is best option select. According to result from the all parameter welding time can
effect significantly on experiments.

51
 Result and Discussion

5.3 Analysis of Variance:

ANOVA or Analysis of Variance is a method to determine which variable affects a

particular output parameter. Though, Regression has p-values, but it doesn’t give as
much accurate results as ANOVA gives.

In ANOVA technique, each term in the equation is taken into account. P-values of
each and every term in the equation is calculated. For the purpose, ANOVA gives p-
values according to hypothesis.

Our confidence level for the equation is taken as 95 %. It means that, if the term has a
p- value of more than 5%, then we can reject it’s influence. In short, if p-value for any
term in ANOVA is higher than 0.05, then we can neglect the influence of that term
and take it out from the equation.

Thus, ANOVA doesn’t only gives us the impact of each and every term, but also, it
helps us in removing the un-necessary terms in the equation and reduce the calculation
time.

In Minitab software, ANOVA was performed simultaneously along with regression

analysis, when we give the command to analyze Taguchi design.

52
 Result and Discussion

5.3.1 ANOVA Analysis for Tensile strength And Nugget Diameter:

Figure 5.12 Open ANOVA in Minitab software

Figure 5.13 General linear model

After that select Tensile strength in responses and select factors welding current, welding
time and electrode force. After that click on OK button. And get regression equation for
tensile strength.

53
 Result and Discussion

5.3.2 ANOVA Analysis of GI/GI with Al inter layer:

Table: 5.1 ANOVA table of tensile strength of Al inter layer

Source N Cycle kA Error

DF 2 2 2 2

Seq. SS 326548 5485496 48123 5653289

value

Contrib 1.54% 91. 04% 1.43% 5.9%

ution

Adj SS 26579 8546 5745 2133

Adj MS 13289 4273 2872 1066

F value 0.330 0.408 0.051

P value 0.0525 0.043 0.049

S 326.548

R-Sq 95.04 %

R-Sq 80.16%
(adj)

R-Sq 18.45%
(Pred)

Regression equation: T.S = 2.830 - 0.580 C_8.25 - 0.147 C_9.35 + 0.727 C_10.45 -
0.177 T_7 - 0.257 T_8 + 0.433 T_9 + 0.197 F_4.2 + 0.160 F_4.6 - 0.357 F_5.0

Table: 5.2 ANOVA for Nugget Diameter of Al inter layer

Source N Cycle kA Error

DF 2 2 2 2

Seq. SS 189632 475136 32234 45123

value

Contrib 15% 67% 6% 12%

ution

54
 Result and Discussion

Adj SS 56519 65465 5423 752

Adj MS 3654 123769 4126 3062

F value 0.378 0.415 0.015

P value 0.0595 0.023 0.042

S 339.692

R-Sq 96.12 %

R-Sq 84.50%
(adj)

R-Sq 21.51%
(Pred)

Regression equation: N.D = 5.4822 + 0.378 C_8.25 - 0.632 C_9.35 + 0.254 C_10.45 -
0.302 T_7 - 0.049 T_8 + 0.351 T_9 + 0.238 F_4.2 - 0.122 F_4.6 - 0.116 F_5.0

5.3.3 ANOVA Analysis of GI/GI with Cu inter layer:

Table: 5.3 ANOVA table of tensile strength of Cu inter layer

Source N Cycle kA Error

DF 2 2 2 2

Seq. SS 15921 687452 7452 8564

value

Contrib 8.47% 89.42% 1.9% 0.21%

ution

Adj SS 3625 541238 4128 3486

Adj MS 3654 784531 4199 2164

F value 0.287 0.319 0.115

P value 0.0577 0.0364 0.242

S 397.442

55
 Result and Discussion

R-Sq 93.74 %

R-Sq 74.96%
(adj)

R-Sq 61.79%
(Pred)

Regression Equation: T.S = 1.638 - 0.218 C_8.25 - 0.144 C_9.35 + 0.362 C_10.45 -
0.154 T_7 - 0.541 T_8 + 0.696 T_9 - 0.368 F_4.2 + 0.072 F_4.6 + 0.296 F_5.0

Table:5.4 ANOVA for Nugget Diameter of Cu inter layer

Source N Cycle kA Error

DF 2 2 2 2

Seq. SS 74931 848463 57632 48632

value

Contrib 7.64% 88.76% 2.6% 1%

ution

Adj SS 4123 74521 66324 3713

Adj MS 3456 48517 39742 2848

F value 0.425 0.515 0.595

P value 0.0549 0.0463 0.0338

S 402.545

R-Sq 91.99 %

R-Sq 63.97%
(adj)

R-Sq 47.92%
(Pred)

Regression equation: N.D = 5.397 - 0.150 C_8.25 + 0.317 C_9.35 - 0.167 C_10.45
+ 0.010 T_7 - 0.490 T_8 + 0.480 T_9 - 0.387 F_4.2 + 0.100 F_4.6 + 0.287 F_5.0

56
 Result and Discussion

5.3.4 ANOVA Analysis of GI/GI with SS inter layer:

Table: 5.5 ANOVA table of tensile strength of SS inter layer

Source N Cycle kA Error

DF 2 2 2 2

Seq. SS 42139 558746 60950 34021

value

Contrib 5.74% 92.09% 1.42% 0.75%

ution

Adj SS 2546 480328 2528 9686

Adj MS 3744 849134 4749 7164

F value 0.189 0.412 0.127

P value 0.0509 0.0396 0.0371

S 200.083

R-Sq 96.20 %

R-Sq 84.80%
(adj)

R-Sq 81.07%
(Pred)

Regression Equation

T.S = 3.7633 + 0.2367 c_8.25 + 0.0400 c_9.35 - 0.2767 c_10.45 - 0.4800 t_7 + 0.0900 t_8
+ 0.3900 t_9 + 0.1767 f_4.2 + 0.1400 f_4.6 - 0.3167 f_5.0

Table:5.6 ANOVA for Nugget Diameter of SS inter layer

Source N Cycle kA Error

DF 2 2 2 2

Seq. SS 74931 848463 57632 48632

value

57
 Result and Discussion

Contrib 1.8% 94.96% 2.6% 0.64%

ution

Adj SS 5139 812365 4752 2716

Adj MS 3456 48517 39742 2848

F value 0.494 0.517 0.553

P value 0.0584 0.0433 0.0298

S 248.752

R-Sq 95.05 %

R-Sq 85.21%
(adj)

R-Sq 77.67%
(Pred)

Regression Equation

N.D = 5.3489 - 0.356 c_8.25 + 0.248 c_9.35 + 0.108 c_10.45 - 0.502 t_7 + 0.058 t_8
+ 0.444 t_9 + 0.214 f_4.2 - 0.296 f_4.6 + 0.081 f_5.0

58
 Result and Discussion

5.4 Response Surface Optimizer:

After the experiments are done, statistical models are developed and analyzed; model
needs to be checked for validation. This shows whether, the model is valid for the given
inputs and outputs or not.

For this need, we will use the option, given in minitab software, that is, ANOVA
Response optimizer.

Figure 5.14 Selection of Response Optimizer

We will use the target method for optimization. We will give the minimum and maximum
input parameters and then the target. Software will give us the input values for desired
target. By doing experiment on the input values and then comparing the output value of
experiment with target, we will validate the statistical model. We will take the criteria of
10 %. If difference between target and result from experiment is more than 10%, then
validation will be failed.

59
 Result and Discussion

5.5 Result of optimization:

Figure.5.15 Optimization plot

It can be seen that From response optimizer, the resulting breaking load is 9.87 kN and
optimum nugget diameter of weld is 5.99 mm are the optimum value of output
parameters.

Optimum input parameters:

➢ Welding current – 9.87 kA

➢ Welding Time – 9 cycles

➢ Electrode Force – 4.2 Kn

Optimum Output Parameter:

➢ Lap shear tensile strength – 4.32 kN

➢ Nugget Diameter – 5.99 mm

60
 Result and Discussion

To validate the results of optimization from software, experiments were carried out using
the optimized input parameters and tested for lap shear tensile strength and Nugget
diamter. The results obtained were as follows:

Table 5.7 validation test

Sr. Parameter Minitab result Experimental Eroor

No result

1 Lap shear 4.32 kN 4.25 kN 1.68 %

tensile
strength

2 Nugget 5.99 mm 5.75 mm 4.01%

Diameter

61
 Conclusion and Future Scope

CHAPTER 6

Conclusion and Future Scope

6.1 Conclusion

From the work above, the suggestions were given to the industry about the input
parameters. It can be said from the above experiments that,

• The main affecting parameters on weld quality for automotive application are welding
current, welding time and electrode force.

• From standards, output parameters decided, which are Lap shear tensile strength and
Nugget diameter.

• With the help of Taguchi Design, statistical model was validated and it was found that,
optimum results for Lap shear tensile strength and Nugget diameter can be found at
9.87 kA current, 9 cycles welding time and 4.2 kN electrode force.

• Experimental validation showed that, the model has the ability to predict results
accurately as the error in lap shear tensile strength is near to 2% and error in Nugget
diameter is less than 5%

6.2 Future Scope:

Future Scope for Resistance Spot Welding will be on the path of machine learning. Based
on optimization algorithms and artificial neural networks, sensors can predict the weld
quality that one will get. Resistance Spot Welding may be seen as a simple process by
manufacturers, but for researchers, it is a very complex process.

62
 References

References

Papers:

1. Sun, M., et al. "Microstructure and mechanical properties of resistance spot

welded

AZ31/AA5754 using a nickel interlayer." Materials & Design 87 (2015): 905-913

2. H.C.Lin, E. V Stephens, M. A. Khaleel, H. Shao, and M. Kimchi, “Resistance

Spot Welding of Aluminum Alloy to Steel with Transition Material - From
Process to Performance - Part 1: Experimental Study,” Welding Journal, Vol. 83,
No. 6, 2004, 188S– 195S

3. Jian chen, T. Wu, and M. Li, “ n Effective pproach for Solving The Multi-
Response Problem in Taguchi Method,” Jordan Journal of Mechanical and
Industrial Engineering, Vol. 4, No. 2, 2010, 314–323.

4. Ihsan kadhom, . ogun, and G. Tosun, “ study on kerf and material removal rate
in wire electrical discharge machining based on Taguchi method,” Journal of
Materials Processing Technology, Vol. 152, No. 3, 2004, 316–322

5. Eaith Hayat, T. Wu, and M. Li, “ n Effective pproach for Solving The Multi-
Response Problem in Taguchi Method,” Jordan Journal of Mechanical and
Industrial Engineering, Vol. 4, No. 2, 2010, 314–323

6. I.H.Hawang and J. ntony, “ pplication of design of experiments to a spot welding

process,” ssembly utomation, Vol. 23, No. 3, 2003, 273-279.

7. H.Oikawa, K. R. Milkey, . R. Samsudin, . K. Dubey, and P. Kidd, “ omparison

between taguchi method and response surface methodology (RSM) in modelling
CO2 laser machining,” Jordan Journal of Mechanical and Industrial Engineering,
Vol. 8, No. 1, 2014, 35–42

8. Ranfeng Qiu, . Loureiro, J. D. M. osta, and P. J. Bártolo, “Effect of process

parameters on the strength of resistance spot welds in 6082-T6 aluminium alloy,”
Materials and Design, Vol. 31, No. 5, 2010, 2454–2463.

9. Manoj raut , Hongxin Shi , Hua Yu and Keke Zhang, “Joining phenomena of
stainless steel / aluminium alloy joint welded by thermal compensation resistance
spot welding” International Journal of Materials and Production Technology, Vol.
49, No. 4, 2014, 285– 293

10. Alaa Muhsin saeed, N.Ramanaiah, M.M.M.Sarcar, Optimization of volumetric

wear rate of AA7075-Ti metal matrix composite by using taguchi technique,”

63
 References

Jordan Journal of Mechanical and Industrial Engineering, Vol. 10, No. 3, 2016,
189–198.

11. J.saguses, B. B. Naik, and K. Sammaiah, “Resistance Spot Weld Quality

haracteristics Improvement By Taguchi Method,” Materials Today: Proceedings,
Vol. 2, No. 4-5, 2015, 2595–2604

12. M.C.Kathartio, K. Kagiya, A. Yanagisawa, and H. Tanabe: Quart. J. Jpn. Weld.

Soc., 2006, vol. 24, pp. 108–15.
13. Prashanthkumar, V.K., Venkataram, N., Mahesh, N.S., & Kumarswami (2014).
Process Parameter Selection for Resistance Spot Welding through Thermal
Analysis of 2 mm CRCA Sheets. Procedia Mater. Sci. 5, 369–378.

14. Aslanlar, S., Ogur, A., Ozsarac, U., & Ilhan, E. (2008). Welding time effect on
mechanical properties of automotive sheets in electrical resistance spot welding.
Mater. Des. 29, 1427–1431

15. Hakan Aydin, L. Liu, Y. Zhou, and S. Esmaieli: Metall. Mater. Trans. A, 2010,
vol. 41A, pp. 1511–22

16. Milan brozek, M.V. Li, and Y. Zhou: Sci. Technol. Weld. Join., 2001, vol. 6, pp.
273–80

17. Arvinthkhan arunmugan, M.L. Kuntz, M.I. Khan, and Y. Zhou: Sci. Technol.
Weld. Join., 2008, vol. 13, pp. 769–76.

18. A.Ambroziak L.M. Liu, L.M. Zhao, and R.Z. Xu: Mater. Des., 2009, vol. 39, pp.
4548–51.

19. Seyedeh nooshin mortazavi.C. Park, Y.S. Sato, and H. Kokawa: Scripta Mater.,
2003, vol. 49, pp. 161–66

20. X.sun, Y. Zhou, and H.W. Kerr: Metall. Mater. Trans. A, 2002, vol. 33A, pp.
2667–76

21. L.liu, S.A. Gedeon and T.W. Eagar: Metall. Trans. B., 1986, vol. 17B, pp. 887–90

22. Kenji miyamiyamoto, D.Q. Sun, B. Lang, D.X. Sun, and J.B. Li: Mater. Sci. Eng.
A, 2007, vols. 460–461, pp. 494–98.

23. Refeng Qiu, R., Iwamoto, C., & Satonaka, S. (2009). Interfacial microstructure and

64
 References

strength of steel/aluminum alloy joints welded by resistance spot welding with

cover plate. J. Mater. Process. Technol. 209, 4186–4193

24. Han, L., Thornton, M., Boomer, D., & Shergold, M. (2011). A correlation study of
mechanical strength of resistance spot welding of AA5754 aluminium alloy. J.
Mater. Process. Technol. 211, 513–521.

25. Pouranvari, M., & Marashi, S.P.H. (2013). Critical review of automotive steels spot
welding: process, structure and properties. Sci. Technol. Weld. Join. 18, 361–403.

26. Sun, H.T., Lai, X.M., Zhang, Y.S., & Shen, J. (2007). Effect of variable electrode
force on weld quality in resistance spot welding. Sci. Technol. Weld. Join. 12,
718– 724

27. Wei, P.S., & Wu, T.H. (2012). Electrical contact resistance effect on resistance spot
welding. Int. J. Heat Mass Transf. 55, 3316–3324

28. Chen, C.C., Hsu, T.C.J., & Ho, N.J. (1994). Resistance spot welding of precoated
steel sheet: Computational heat-transfer analysis. Metall. Mater. Trans. B 25, 415–
423

29. Li, Y., Lin, Z., Hu, S.J., & Chen, G. (2008). Magnetohydrodynamic behaviors in a
resistance spot weld nugget under different welding currents. Sci. China, Ser. E
Technol. Sci. 51, 1507–1515

30. Wan, X., Wang, Y., & Zhang, P. (2014). Modelling the effect of welding current
resistance spot welding of DP600 steel. J. Mater. Process. Technol. 214, 2723–
2729

Websites:

31. Kriton Welding Manufacturers Booklet, www.kriton-welding.com/brochure.pdf

32. Ruuki Welding Manufacturers Manual,

www.ruuki.com/resistance_welding_manual.pdf.

Standards:

33. ASME SECTION IX, American Society of Mechanical Engineers.

65
 Appendix A: Review card

66
 Appendix A: Review card

67
 Appendix A: Review card

68
 Appendix A: Review card

69
 Appendix A: Review card

70
 Appendix A: Review card

71
 Appendix B: Compliance Report

Appendix B: Compliance Report

Comments given during Dissertation Phase-1 and Mid-Sem Review are given below
with required actions taken for their fulfilment:

 Comments for Dissertation Phase – 1:

Sr. No. Comments Given Actions

1 Deep study of literature is required. Studied
2 Modify the title. Done
3 Pilot experiments to identify the Done
parameter range.
4 Basic of engineering need to Studied
improve.
5 Different material for sandwich is Considered
required.
6 Nugget study is required as one of Measured
the output parameter.
7 To study heat balance for spot weld Done
for sandwich panel.

Comments for Mid-Semester Review:

Sr. No. Comments Given Actions

1 Improve knowledge of Studied

fundamentals
2 Work is satisfactory Done

3 How have you measured the Measured

nugget diameter

72
 Appendix C: Paper Publication

73
 Appendix D: Standards

Front Page

74
 Appendix D: Standards Result

Page 198

75
 Appendix D: Standards Result

Test Result:

76
 Appendix D: Standards Result

77
 Appendix E: Plagiarism Report

78
 Appendix E: Plagiarism Report

79
80