Abstract

This study aims to find the best conditions of resistance spot welding in commercialAluminium AA1050 to obtain the maximum tensile shear strength of the joint using a lowpowersupply welding machine. The chosen parameters for this study were welding current,welding time, and electrode force using a 90 kVA welding machine. The investigation usedthe DoE method with Taguchi’s technique to reduce the number of experiments where twosheet thicknesses (1 mm and 2 mm) were used in this work. The software program Minitab18 analyzed the results using the main effects plots and the interaction plots to identify themost significant parameters and their effect on the joint strength. The best conditions formaximum tensile shear force were 14.85 kA welding current and 0.79 kN electrode force forboth thicknesses and two cycles and 12 cycles welding time for 1 mm and 2 mm sheetthickness, respectively. The maximum tensile strength obtained was 250 N and 225 N for1mm and 2mm sheet thickness, respectively. A mathematical equation was developed topredict the shear force with 19.9 % and 17.9 % error for 1 mm and 2 mm thicknesses,respectively. The best conditions were applied in ANSYS 2022R1 multi-physics to obtain thetemperature distribution with time history, where the result shows the nugget sizeaccording to the molten temperature. The percentage of discrepancy between actual andnumerical nugget size was 8 %.

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The article was added to IASJ on 2024-04-08

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