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1. INTRODUCTION

Resistance welding is a thermo-electric process in which heat is generated at the

interface of the parts to be joined by passing an electrical current through the parts for
a precisely controlled time and under a controlled pressure (also called force). The
name resistance welding derives from the fact that the resistance of the work pieces
and electrodes are used in combination or contrast to generate the heat at their
interface. Resistance welding is a fairly simple heat generation process; the passage of
current through a resistance generates heat [9]. This is the same principle used in the
operation of heating coils. In addition to the bulk resistances, the contact resistances
also play a major role. The contact resistances are influenced by the surface condition
(surface roughness, cleanliness, oxidation, and platings).

Bulk resistance is a function of temperature. All metals exhibit a Positive Temperature

Coefficient (PTC), which means that their bulk resistance increases with temperature.
Bulk resistance becomes a factor in longer welds. Contact resistance is a function of
the extent to which two surfaces mate intimately or come in contact. Contact
resistance is an important factor in the first few milliseconds of a weld. The surfaces of
metal are quite rough if they are examined on a molecular scale. When the metals are
forced together with a relatively small amount of force, some of the peaks make
contact. On those peaks where the contact pressure is sufficiently high, the oxide layer
breaks, forming a limited number of metal-to-metal bridges. The weld current is
distributed over a large area as it passes through the bulk metal. However, as it
approaches the interface, the current is forced to flow through these metallic bridges.
This necking down increases the current density, generating enough heat to cause
melting. As the first of these bridges melt and collapse, new peaks come into contact,
forming new bridges and additional current paths. The resistance of the molten metal
is higher than that of the new bridges so that the current flow transfers from bridge-to-
bridge. This process continues until the entire interface is molten. When the current
stops, the molten metal cools rapidly thus forming a weld [9].

Key advantages of the resistance welding process include:

Very short process time.

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No consumables, such as brazing materials, solder, or welding rods.

Operator safety because of low voltage.
Clean and environmentally friendly.
A reliable electro-mechanical joint is formed.

Fig. 1.1 Resistance Welding

1.1 Types of Resistance Welding:

Depending on the shape of the work pieces and the form of the electrodes, resistance
welding processes can be classified into several variants as described below:

Resistance Spot Welding (RSW)

Resistance Seam Welding
Resistance Projection Welding
Resistance Butt Welding
Percussion Welding
High Frequency Resistance Welding
Low Frequency Resistance Welding
Resistance Weld Bonding

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1.2 Resistance Spot Welding:

Spot welding is one form of resistance welding, which is a method of welding two or
more metal sheets together without using any filler material by applying pressure and
heat to the area to be welded. The process is used for joining sheet materials and uses
shaped copper alloy electrodes to apply pressure and convey the electrical current
through the work pieces. In all forms of resistance welding, the parts are locally
heated. The material between the electrodes yields and is squeezed together. It then
melts, destroying the interface between the parts. The current is switched off and the
"nugget" of molten materials solidifies forming the joint [2].

Fig. 1.2.1 Resistance Spot welding

The principle of resistance welding is based on Joule heating. The work pieces are
clamped between the electrodes by applying an electrode force, then an electric current
passes through the top and bottom electrodes and heats the work pieces by Joule
heating. When the temperature at the interface reaches the melting point of the
material, a molten nugget begins to form and grow. When the welding current is
switched off, this nugget will solidify to form a weld that joins the work pieces
together. Figure 1.2.2 shows the general setup and procedure of the resistance spot
welding with the two electrodes. The process is used extensively for joining low and
mild carbon steel sheet metal components for automobiles, cabinets, furniture and
similar products. Stainless steel, aluminium and copper alloys are also spot welded
commercially. Excessive heating in resistance welding results in metal expulsion

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during the welding operation. Since accurate method for selection of welding variables
i.e. welding current, welding time and electrode force, thickness of sheet, electrode
type, electrode tip diameter, gap in the electrodes, shape of electrode tip, electrode
material etc. are lacking [1].

There are various factors involves resistance spot welding process which are
responsible for the quality of weld. Depending on the thickness and type of the metal,
welding conditions such as weld current, weld time, electrode type and electrode force
should be adjusted [10].

Fig. 1.2.2 General Setup of Resistance Spot Welding

Generally, a weld cycle can be divided into a number of stages:

Pre-squeeze stage (1 to 2)
Squeeze stage (2 to 3)

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Weld stage (3 to 4)
Hold stage (4 to 5)
Release stage (5 to 6)

In the Pre-squeeze stage, the moving electrode closes towards the work pieces,
resulting in contact between the electrodes and work pieces. The velocity of the
electrodes at this point of impact is very important considering that too high impact
energy will results in excessive electrode wear [8].

In the squeeze stage, the electrodes are forced on the work piece surfaces by means of
the force actuating system and this offers the possibility to deform the work piece to
ensure sound contact between them.

Fig. 1.2.3 Welding cycle of RSW process

In the weld stage, while force remains on the work pieces, current will be flowing
through the electrodes and the work piece, heating up every part in the secondary weld
circuit proportional to the effective resistance present at each point.

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In the hold stage, the current is cut off and produced weld is allowed to solidify and
cool down under maintain pressurizing force. After sufficient holding time, the
electrodes release the work piece and the cycle is complete.

The major advantages of the resistance spot welding processes over any other welding
process is the feature that heat necessary for weld formation is generated at the exact
location where the joints needs to appear. The possibility to highly reduce the time to
complete a weld resulting in cycle times being competitive over other welding process.
The another advantage is the absence of a molten weld pool penetrating from one side
through a work piece, resulting in less aesthetical damage to the work piece surfaces
[8].

1.2.1 Resistance Spot Welding Parameters:

a. Electrode Force:

The purpose of the electrode force is to squeeze the metal sheets to be joined together.
This requires a large electrode force because else the weld quality will not be good
enough. However, the force must not be too large as it might cause other problems.
When the electrode force is increased the heat energy will decrease. This means that
the higher electrode force requires a higher weld current. When weld current becomes
too high spatter will occur between electrodes and sheets. This will cause the
electrodes to get stuck to the sheet.

An adequate target value for the electrode force is 90 N/mm2. One problem, though, is
that the size of the contact surface will increase during welding. To keep the same
conditions during the whole welding process, the electrode force needs to be gradually
increased. As it is rather difficult to change the electrode force in the same rate as the
electrodes are "mushroomed", usually an average value is chosen [9].

b. Diameter of the electrode contact surface:

One general criterion of resistance spot-welding is that the weld shall have a nugget
diameter of 5*t1/2, t being the thickness of the steel sheet. Thus, a spot weld made in

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two sheets, each 1 mm in thickness, would generate a nugget 5 mm in diameter

according to the 5*t-rule. Diameter of the electrode contact surface should be slightly
larger than the nugget diameter. For example, spot welding two sheets of 1 mm
thickness would require an electrode with a contact diameter of 6 mm. In practice, an
electrode with a contact diameter of 6 mm is standard for sheet thickness of 0.5 to 1.25
mm. This contact diameter of 6 mm conforms to the ISO standard for new electrodes
[6].

c. Squeeze time:

Squeeze Time is the time interval between the initial application of the electrode force
on the work and the first application of current. Squeeze time is necessary to delay the
weld current until the electrode force has attained the desired level [8].

d. Weld time:

The rate of heat generation must be such that welds with adequate strength will be
produced without excessive electrode heating and rapid deterioration. The total heat
developed is proportional to weld time. During a spot welding operation, some
minimum time is required to reach melting temperature at some suitable current
density.

Fig. 1.2.1.1 Tensile-shear strength as a function of weld time

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Excessively long weld time will have the same effect as excessive amperage on the
base metal and electrodes. Furthermore, the weld heat-affected zone will extend
farther into the base metal. The relationship between weld time and spot weld shear
strength is shown in Fig. 1.2.1.1 assuming all other conditions remain constant. To a
certain extent, weld time and amperage may be complementary. The total heat may be
changed by adjusting either the amperage or the weld time. Heat transfer is a function
of time and the development of the proper nugget size requires a minimum length of
time, regardless of amperage [4].

e. Hold time (cooling-time):

Hold time is necessary to allow the weld nugget to solidify before releasing the welded
parts, but it must not be too long as this may cause the heat in the weld spot to spread
to the electrode and heat it. The electrode will then get more exposed to wear. Further,
if the hold time is too long and the carbon content of the material is high (more than
0.1%), there is a risk the weld will become brittle [9].

f. Weld current:

The weld current is the current in the welding circuit during the making of a weld. The
amount of weld current is controlled by two things; first, the setting of the transformer
tap switch determines the maximum amount of weld current available; second the
percent of current control determines the percent of the available current to be used for
making the weld.

Low percent current settings are not normally recommended as this may impair the
quality of the weld. Tensile shear strength increases rapidly with increasing current
density. Excessive current density will cause molten metal expulsion (resulting in
internal voids), weld cracking, and lower mechanical strength properties.

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Fig. 1.2.1.2 Effect of welding current on spot weld shear strength

Typical variations in shear strength of spot welds as a function of current magnitude

are shown in Fig. 1.2.1.2. In the case of spot welding excessive current will overheat
the base metal and result in deep indentations in the parts and, it will cause
overheating and rapid deterioration of the electrodes [3].

g. Contact Resistance:

The contact resistance at the weld interface is the most influential parameter related to
materials. It however has highly dynamic interaction with the process parameters. The
figure below shows the measured contact resistance of mild steel at different
temperatures and different pressures. It is noticed that the contact resistance generally
decreases with increasing temperature but has a local ridge around 300C, and it
decreases almost proportionally with increasing pressure. All metals have rough
surfaces in micro scale.

When the welding force increases, the contact pressure increases thereby the real
contact area at the interface increases due to deformation of the rough surface
asperities. Therefore the contact resistance at the interface decreases which reduces the
heat generation and the size of weld nugget. On the metal surfaces, there are also
oxides, water vapour, oil, dirt and other contaminants. When the temperature
increases, some of the surface contaminants (mainly water and oil based ones) will be

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burned off in the first couple of cycles, and the metals will also be softened at high
temperatures. Thus the contact resistance generally decreases with increasing
temperature. Even though the contact resistance has most significant influence only in
the first couple of cycles, it has a decisive influence on the heat distribution due to the
initial heat generation and distribution.

h. Surface coatings:

Most surface coatings are applied for protection of corrosion or as a substrate for
further surface treatment. These surface coatings often complicate the welding
process. Special process parameter adjustments have to be made according to
individual types of the surface coatings. Some surface coatings are introduced for
facilitating the welding of difficult material combinations. These surface coatings are
strategically selected to bring the heat balance to the weld interface. Most of the
surface coatings will be squeezed out during welding, some will remain at the weld
interface as a braze metal [9].

Fig. 1.2.1.3 Cause and effect diagram of main welding parameters

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2. LITERATURE REVIEW

B.D. Gurav & S.D. Ambekar presented a paper Optimization of the Welding
Parameters in Resistance Spot Welding International Journal of Mechanical
Engineering and Technology (IJMET), Volume 4, September - October (2013) [2].
They studied on the optimization and the effect of the welding parameters (welding
current, welding time, & electrode force) on the tensile shear strength of the resistance
spot welded joints for using CRCA (close rolled close annealing) steel sheets with
2mm thickness. For using orthogonal array of Taguchi method, the signal-to-noise
ratio, the analysis of variance (ANOVA) employed to find the optimal process
parameters levels and to analyse the effect of these parameters on tensile shear
strength values. At last for the experimental setup and results to show that the input
parameters are high current, medium electrode force and high weld time. The welding
current is the most effective factor in spot welding process. The contribution of
welding current, weld time and electrode force towards tensile strength is 49.72%,
42.19%, and 7.85% respectively as determined by the ANOVA method.

Norasiah Muhammad and Yupiter HP Manurung presented a paper Design

parameters selection and Optimization of weld zone development in Resistance Spot
Welding World Academy of Science, Engineering and Technology 71 2012 [4]. They
have been investigates the development of weld zone in Resistance Spot Welding. The
work piece material used in this study was 1.21mm thick coated low carbon steel as
the base metal. A general 24 factorial design augmented by 5 centre points was used to
study the effect of factors namely weld current, weld time, electrode force and hold
time on the development of weld zone. Optimization of the significant parameters
affecting the development of weld zone obtained from the factorial design was carried
out using CCD (Central Composite Design) in Response Surface Method. An
experimental design was used to determine the effects of welding parameters (weld
current, weld time, electrode force and hold time) on the development of the weld
zone. On the results define that all the selected factors expect hold time affected the
radius of weld nugget and HAZ (Heat Affected Zone) significantly and optimized
using the Central Composite Design by RSM. A quadratic model of for radius of weld
nugget and radius of HAZ were developed. The experimental results obtained under

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optimum operating conditions were compared with the predicted values and found to
agree satisfactorily with each other.

D.S.Sahota, Ramandeep Singh, Rajesh Sharma published a paper Study of Effect

of Parameters on Resistance Spot Weld of ASS316 Material ISSN: 2320-2491 Vol. 2,
No. 2, February-March 2013 [1]. The objective of this work was to study the effect of
parameters on resistance spot weld of ASS316 material. In order to study the
significance of the process parameters i.e. current, electrode force and weld cycles,
towards the percentage improvement in material hardness. It was clear from the results
that parameters significantly affect both the mean and the variation in the percentage
improvement in Hardness values of the ASS316 material. The S/N ratio analysis
suggests third level of weld current, third level of weld cycle and third level of
electrode force as the best levels for maximum percentage improvement in hardness of
ASS316 work-piece in spot welding operation.

Aravinthan Arumugam, Mohd. Amizi Nor presented a paper Spot Welding

Parameter Optimization to Improve Weld Characteristics for Dissimilar Metals
International journal of scientific & technology research volume 4, issue 01, January
2015 [3]. This work concentrates on the parameter optimization when spot welding
steels with dissimilar thickness and type using Grey Based Taguchi Method. The
experimentation in this work used a L9 orthogonal array with three factors with each
factor having three levels. The three factors used are welding current, weld time and
electrode force. The three weld characteristics that were optimized are weld strength,
weld nugget diameter and weld indentation. The analysis of variance (ANOVA) that
was carried out showed that welding current gave the most significant contribution in
the optimum welding schedule. The comparison test that was carried out to compare
the current welding schedule and the optimum welding schedule showed distinct
improvement in the increase of weld diameter and weld strength as well as decrease in
electrode indentation.

J.B. Shamsul and M.M. Hisyam presented a paper Study of Spot Welding of
Austenitic Stainless Steel Type 304 School of Materials Engineering, University
Malaysia Perlis, Journal of Applied Sciences Research, 2007, INSI net Publication [5].

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On this study paper, austenitic stainless steel type 304 was welded by resistance spot
welding. It was investigated the relationship between of the nugget diameter and
welding current and also Hardness distribution along welding zone. They used
Austenitic SS304 of 3mm thickness. The experimental result showed that the changes
of the current, the nugget diameter were changed. So it is proven that the weld nugget
increases with the increasing of welding current. Micro hardness testing was used to
carried out on the cross section samples across the horizontal & vertical of the nugget
the graphs were studied to show that the weld nuggets due to the varied welding
current. Austenitic stainless steel AISI-304 is an extremely important commercial
alloy due to its excellent corrosion resistance, high strength, good ductility and
toughness. The results showed that increasing welding current increased the nugget
size. The nugget size did not influence the hardness distribution. In addition,
increasing welding current does not increase the hardness distribution.

K. Pandey, M. I. Khan, K. M. Moeed published a paper Optimization of Resistance

Spot Welding Parameters Using Taguchi Method Integral University, Lucknow,
India. International Journal of Engineering Science and Technology (IJEST), ISSN:
0975-5462 Vol. 5 No.02 February 2013 [6]. In this research they have represented the
optimization of various process parameters of resistance spot welding process. The
material used is low carbon cold rolled 0.9mm mild steel sheets (AISI 1008/ASTM
A366). For the experimental setup and investigation of varying process parameters
(welding current, welding pressure, and welding time) to effect of the quality
characteristic (tensile strength) using Taguchi Method. An experimental result showed
that, S/N ratio to tensile strength indicates the welding current to be the most
significant parameter that controls the weld tensile strength where the holding time
and pressure are less. The contribution of Welding current, holding time and Pressure
towards tensile strength was 61%, 28.7%, and 4% determined by the ANNOVA
method.

Manoj Raut and Vishal Achwal presented a paper Optimization of Spot Welding
Process Parameters for Maximum Tensile Strength International Journal of
Mechanical Engineering & Robotics Research ISSN 2278 0149 Vol. 3, No. 4,
October 2014 [7]. This experimental study was based on an investigation of the effect

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and optimization of welding parameters on the tensile shear strength in the Resistance
Spot Welding (RSW) process. The experimental studies were conducted under varying
electrode forces, welding currents, and welding times. The settings of welding
parameters were determined by using the Taguchi experimental design of L18
Orthogonal array method. The combination of the optimum welding parameters have
determined by using the analysis of Signal-to-Noise (S/N) ratio. The confirmation test
performed clearly showed that it is possible to increase the tensile shear strength of the
joint by the combination of the suitable welding parameters. Hence, the experimental
results confirmed the validity of the used Taguchi method for enhancing the welding
performance and optimizing the welding parameters in resistance spot welding
operations.

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3. PROBLEM STATEMENT

In electrical industries Resistance Spot Welding process plays an important role in

joining the sheet metals. There is a great demand for obtaining good quality weld joint
in order to have defect free product. Distribution box is made up of different sheet
metal thickness, which requires process parameters to be varied. Therefore following
are the problems associated with the optimization of spot welding:-

Tendency of alloying with the electrode resulting in increased tool wear, and
subsequent deterioration of weld quality.

More current and time lead to expulsion and overheating of the electrode
affecting the weld quality and less value result in insufficient weld strength.

Weld time should be as short as possible.

The weld current should give the best weld quality as possible.

The weld parameters should be chosen to give as little wearing of the

electrodes as possible.

The weld time shall cause the nugget diameter to be big when welding thick
sheets.

Diameter of the electrode contact surface should be slightly larger than the
nugget diameter.

Interfacial mode (or nugget fracture) is the fracture of the weld nugget through
the plane of the weld; the dominant failure mode for small diameter spot welds.

Nugget pull-out mode (or sheet fracture) is the fracture of the sheet around the
weld; the nugget remains intact; dominant for large diameter spot welds.

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Excessive heat in the electrodes reduces the electrode cap life and deteriorates
the weld quality.

Fig. 3.1 Problem of Weld open in VTPN DB

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4. OBJECTIVE & SCOPE OF THE PROJECT

4.1 Objectives:

This project work is intended for the following objectives:

i. To study the basics of Resistance Welding Processes.

ii. To Study Heat Generation & Control.

iii. To Study Spot Welding Process and its Application.

iv. To study the optimization technique by using Minitab.

v. Requirement for quality assurance.

vi. Validation of experiment using optimization to standardize process parameter.

vii. To enhance the weld strength in VTPN DB.

4.2 Scope:

The basic aim of the project work is to optimize resistance spot welding process
parameters to avoid mechanical failure in VTPN DB.

The Scope of this work is to:

i. Find the optimum parameters to optimize the size of weld nugget and Heat
Affected Zone.

ii. Study; understand the theory and controlling of mechanical response of

resistance spot dissimilar welds.

iii. Apply Design of Experiment (DoE) methodologies to develop mathematical

models for prediction of responses and optimization.

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iv. Predict, compare the developed model for optimization of various process
parameters.

v. Develop a mathematical relationship between the process input parameters and

the output variables in order to optimize the input parameters that lead to the
desired quality of weld.

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5. METHODOLOGY

To identify the stages where

failure occurs

Study existing contact spot

welding process

To create a mathematical
model using process
parameters

Solving the equation using

optimization solver

Validation of Optimization
Result

Optimization

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6. CONCLUSION

i. Resistance Spot welding is quick and easy process, no need to use any fluxes
or filler metal to create a join and also there is no dangerous open flame.

ii. Resistance Spot welding process mainly depends on process parameters (e.g.
welding current, weld time, electrode force), material parameters (e.g. types,
thickness).

iii. The most of the parametric study has been done by considering the three
process parameters such as weld time, applied force and squeeze time and weld
quality has been evaluated with respect to the individual properties such as
tensile shear strength, tensile peel strength etc.

iv. The literature review infers that there is a need to study the effects of all
process parameters on the weld quality and weld strength in detail. At the some
of the research papers concluded that current is the major factor to affect of the
weld quality and weld strength by increasing/decreasing others parameters.

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REFERENCES

1. D.S.Sahota, Ramandeep Singh, Rajesh Sharma, Study of Effect of Parameters on

Resistance Spot Weld of ASS316 Material, ISSN: 2320-2491, Vol. 2, No. 2,
pp.68- 77, February-March 2013.

2. B.D.Gurav & S.D.Ambekar Optimization of the Welding Parameters in Resistance

Spot Welding International Journal of Mechanical Engineering and Technology
(IJMET), Volume 4, September - October (2013).

3. Aravinthan Arumugam, Mohd. Amizi Nor Spot Welding Parameter Optimization

to Improve Weld Characteristics for Dissimilar Metals International journal of
scientific & technology research volume 4, issue 01, January 2015.

4. Norasiah Muhammad and Yupiter HP Manurung Design parameters selection and

Optimization of weld zone development in Resistance Spot Welding World
Academy of Science, Engineering and Technology 71 2012.

5. J.B. Shamsul and M.M. Hisyam Study of Spot Welding of Austenitic Stainless
Steel Type 304 School of Materials Engineering, University Malaysia Perlis,
Journal of Applied Sciences Research, 2007, INSI net Publication.

6. K. Pandey, M. I. Khan, K. M. Moeed Optimization of Resistance Spot Welding

Parameters Using Taguchi Method Integral University, Lucknow, India.
International Journal of Engineering Science and Technology (IJEST), ISSN: 0975-
5462 Vol. 5 No.02 February 2013.

7. Manoj Raut and Vishal Achwal presented a paper Optimization of Spot Welding
Process Parameters for Maximum Tensile Strength International Journal of
Mechanical Engineering & Robotics Research ISSN 2278 0149 Vol. 3, No. 4,
October 2014.

8. B. S. Gawai and Dr. C. M. Sedani Optimization of Process Parameters for

Resistance Spot Welding Process of HR E-34 Using Response Surface Method
International Journal of Science and Research (IJSR) Volume 5 Issue 3, March
2016.

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9. Fundamentals of Small Parts Resistance Welding- AMADA Miyachi Co., Ltd.

10.A.S.Panchakshari, Dr.M.S.Kadam Comparative Study of Responses of Resistance

Spot Welding Obtained From Genetic Algorithm, Response Surface and D-
Optimal Method International Journal of Engineering Science and Innovative
Technology (IJESIT) Volume 2, Issue4, July 2013, ISSN: 2319-5967).

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