Effect of Process Parameter on Tensile Strength of Spot Welded S235 Sheet Using Simulation and Experimental

This study focused on investigation of the effect of process parameter to the tensile strength of a spot welded S235 low carbon steel through simulation and experiment. Resistance spot welding (RSW) is commonly used in joining metal sheets due to its key capabilities, which is time and cost effective as well as high adaptability for automation. However, strength and reliability of a spot welded joint especially in an auto vehicle can be unpredictable. Premature failure of a spot welded joint can be difficult to be predicted but common factors that had been discussed in many research is related with fatigue and residual stress. Process parameter is recognized as one of critical factors affecting the reliability and quality of a spot welded joint. Different type of material and thickness may require different set of parameter to achieve an optimum result. Experimental procedure alone to demonstrate and investigate the effect could be too costly and time inefficient. Therefore, design of experiment and non-linear FEM simulation analysis were used to analyze and validate the result. This study shows the significance of process parameters such as weld current and electrode pressure to the strength of a spot welded joint and accurate setting is needed prior to the welding process to achieve an optimum result.