Experimental investigation and optimization of electrical resistance spot welding process parameters on dissimilar weldments

Abstract

Nowadays there are different types of welding processes such as TIG, MIG and laser are used for joining of various alloys in automobiles, household appliances, and shipbuilding industries. Among these processes, the ERSW process is widely used for welding of stainless steel, mild steel and aluminium alloy sheets, which cannot be welded by other joining processes because of its small thickness. The automobile industries are presently using Stainless Steel (AISI304), Mild Steel (AISI1020) and aluminum alloys (AA2024). The welding of these alloys is facing greater challenges. In this work AISI304(SS), AISI1020(MS) and AA2024(Al) are selected as base materials because they are widely used in commercial applications. The weldability of the above alloys using ERSW process is difficult, because of the selection of unsuitable weld process parameters, which may result in various weld defects. Therefore, it is very important to analyze the influence of various weld process parameters such as power, pressure and time on the mechanical properties, metallurgical characteristics and nugget dimensions of the welded joints. newline