Investigating and Optimizing Resistance Welding Conditions for Superior Weld Quality in HSLA Material

Abstract

This study explores the optimization of resistance welding parameters to achieve superior weld quality in high-strength steel sheets used in automotive structures. By utilizing a Taguchi L9 orthogonal array for design of experiments (DoE), key process parameters—welding current, electrode force, and welding time—were varied and their effects on weld quality indicators such as nugget diameter, tensile shear strength, and weld indentation were evaluated. Analysis of variance (ANOVA) was conducted to identify the most influential parameters. Scanning Electron Microscopy (SEM) and metallographic analysis were used to evaluate the microstructural characteristics of the weld zone. The optimized parameters resulted in a significant improvement in both mechanical performance and weld integrity, confirming the effectiveness of statistical optimization in resistance spot welding (RSW) applications.