Optimization

of Resistance Spot
Welding (RSW) on Automotive
Sheet Metal Parts
Danial Amjad
2017-MS-MED-26
Assignment of Research Methodology
Submitted to Dr. Muhammad Asif Mahmood Qureshi
1.Objective
Optimize the resistance spot
welding (RSW) operation on
automotive sheet metal by
studying and experimentally
examining the response of
different parameter of process to
obtain defect free parts.
2.Literature Review

2.1.Welding:
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics, by causing fusion, which is distinct
from lower temperature metal-joining techniques such as brazing and
soldering, which do not melt the base metal.
2.1.1.Welding Classification

WELDING

RESISTANCE ARC
WELDING WELDING

PROJECTION GMAW
SPOT WELDING
WELDING WELDING
2.2.Resistance Spot Welding (RSW)
Resistive spot welding (RSW) is a
process in which contacting metal
surfaces are joined by the heat
obtained from resistance to electric
current.
2.2.1. Welding Parameters
Spot Welding (4+1) important Basic spot welding parameter
parameters setup formula
1. Current (amp) J=i^2r t
2. Pressure
3. Current time
4. Tip control
5. Tip Cooling
2.2.1. Welding Parameters
Off
Squeeze Time Weld Time Hold Time

Force
Squeeze
Weld Time Hold Time Time
Time

Current
Time
2.2.1.1.Tip Control
Effect of tip shape edge

Too Small Perfect Too Large

Surface melt. 6 mm~8 mm. Unable to make nugget.

Weld Strength weak. Current per unit area is
Tip stick. less.
Tip consumption high.
2.2.1.1Tip Control
Adjust the both tips in parallel for
square alignment with the steel plate.
Square
alignment OK!

Square
alignment NG!
2.2.1.2.Tip Cooling
Water Inlet Water Outlet. RECOMMENDED

1. Proper cooling is required

for tip during welding
process.

2. Water circulation is required

from the tip to avoid tip
heating effect.

ELECTRODE COOLING STANDARD

X NG v Cooling water (for cooling the
electrodes).
Temperature 10~30 C
Water quantity 2~3 Lit/min
2.3.RSW Defects
Some specific defects which normally observed during spot welding
process.
1. Burn-through (spatter)
2. Crack & Holes
3. Mislocated Edge Weld
4. Excessive indentation (Dent)
5. Non round Welds
6. Sheet Metal distortion
7. Sticking, Stuck Tips
Literature review still continued to make strong
background and formulate a research problem.
Thanks!