OPTIMIZATION OF WELDING PARAMETERS OF ELECTRICAL RESISTANCE SPOT WELDED 6082-7075 ALUMINIUM JOINTS USING THE TAGUCHI METHOD
Keywords:
resistance spot welding, aluminium, Taguchi method
Abstract
In this study, aluminium alloys of AA6082 and AA7075 series were welded with resistance spot welding. Effects of welding current intensity, welding time, and electrode pressure on the tensile strength and microstructure were examined, and their optimized values were determined using the Taguchi method. While performing optimization, the L24 orthogonal array was used with the Taguchi method. With this array, the signal/noise (S/N) ratio became the determining factor in controlling the optimization results. Comparing the experimental procedures and analysis results, the results obtained from the real application and Taguchi analysis were found out to be similar.
References
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19Brandt J. Ruszkiewicz, Laine Mears, John T. Roth, “Investigation of Heterogeneous Joule Heating as the Explanation for the Transient Electroplastic Stress Drop in Pulsed Tension of 7075-T6 Aluminum,” Journal of Manufacturing Science and Engineering, Vol. 140, pp. 091014-1-091014-11, SEPTEMBER 2018, DOI: 10.1115/1.4040349
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2Chao YJ. Ultimate strength and failure mechanism of resistance spot weld subjected to tensile, shear, or combined tensile/shear loads. J Engng Mater Technol 2003; 125(2): 125–132.
3Hassanifard S and Zehsaz M. The effect of residual stresses on the fatigue life of 5083-O aluminum alloy spot welded joints. Fatigue 2010; 2(1): 1077–1085.
4Sun X, Stephens EV and Khaleel MA. Effect of fusion zone size and failure mode on peak load and energy absorption of advanced high strength steel spot welds under lap shear loading conditions. Engng Failure Analysis 2008; 15(4): 356–367.
5C.-W. Ji, I. Jo, H. Lee, I.-D. Choi, Y. do Kim, and Y.-D. Park, “Effects of surface coating on weld growth of resistance spot-welded hot-stamped boron steels,” J. Mech. Sci. Technol., vol. 28, no 11, pp. 4761–4769, 2014.
6S. K. Panda, J. Li, V. H. B. Hernandez, Y. Zhou, and F. Goodwin, “Effect of weld location, orientation, and strain path on forming behavior of AHSS tailor welded blanks,” J. Eng. Mater. Technol. Trans. ASME, vol. 132, no. 4, pp. 1–11, 2010.
7S. Smith, N. J. den Uijl, T. Okada, T. van der Veldt, M. Uchihara, and K. Fukui, “The Effect of Ageing on the spot weld strength of AHSS and the consequences for testing procedures,” Weld. World, vol. 54, no. 1, pp. R12–R26, 2010.
8Y. Li, Z. Lin, Q. Shen, and X. Lai, “Numerical analysis of transport phenomena in resistance spot welding process,” J. Manuf. Sci. Eng., vol. 133, no. 3, 2011.
9M. Pouranvari and S. P. H. Marashi, “Critical review of automotive steels spot welding: Process, structure and properties,” Sci. Technol. Weld. Join., vol. 18, no. 5, pp. 361–403, 2013.
10J. Černelič, R. Brezovnik, J. Ritonja, D. Dolinar, and M. Petrun, “Optimal operating point of medium frequency resistance spot welding systems,” 2017 IEEE 26th International Symposium on Industrial Electronics (ISIE), 2017, pp. 2131–2137.
11K. Zhou and L. Cai, “Online measuring power factor in AC resistance spot welding,” IEEE Trans. Ind. Electron., vol. 61, no 1, pp. 575–582, 2014.
12X. Wang, K. Zhou, and S. Shen, “Intelligent parameters measurement of electrical structure of medium frequency DC resistance spot welding system,” Measurement, vol. 171, no. 108795, 2021.
13U. Eşme, “Application of taguchi method for the optimization of resistance spot welding process,” Arab. J. Sci. Eng., vol. 34, no. 2 B, pp. 519–528, 2009.
14R. K. Verma, P. K. Kharwar, A. K. Mondal, K. Abhishek, and J. Kumar, “Exploration of MOORA based hybrid Taguchi Method for Multi-response Optimization—A case study BT - Advances in Mechanical Engineering,” in Advances in Mechanical Engineering Select Proceedings of ICRIDME 2018, B. B. Biswal, B. K. Sarkar, and P. Mahanta, Eds. Singapore: Springer Singapore, 2020, pp. 515–525.
15A. G. Thakur and V. M. Nandedkar, “Optimization of the resistance spot welding process of galvanized steel sheet using the taguchi method,” Arab. J. Sci. Eng., vol. 39, no. 2, pp. 1171–1176, 2014.
16M.R. Arghavani, M. Movahedi, A.H. Kokabi, “Role of zinc layer in resistance spot welding of aluminium to steel,” Materials&Design, volüme 102, 15 July 2016, Pages 106-114
17H. Li, W. Yan, Z. Li, B. Mariusz, J. Senkara, Y. Zhang, “ Numerical and experimental study of the hot cracking phenomena in 6061/7075 dissimilar aluminum alloy resistance spot welding” Journal of Manufacturing Processes, 77, pp. 794–808, 2022
18Esther T. Akinlabi, Stephen A. Akinlabi, K. Surekha, “Effect of friction stir processing on the electrical resistivity of AA 6082,” 2013 Africon, IEEEXplore, DOI:10.1109/AFRCON.2013.6757689
19Brandt J. Ruszkiewicz, Laine Mears, John T. Roth, “Investigation of Heterogeneous Joule Heating as the Explanation for the Transient Electroplastic Stress Drop in Pulsed Tension of 7075-T6 Aluminum,” Journal of Manufacturing Science and Engineering, Vol. 140, pp. 091014-1-091014-11, SEPTEMBER 2018, DOI: 10.1115/1.4040349
20N. Masmiati and A. A. D. Sarhan, “Optimizing cutting parameters in inclined end milling for minimum surface residual stress – Taguchi approach,” Measurement, vol. 60, pp. 267–275, 2015.
21M. Kekik, S.Aslanlar, S. Apay, “ AHSS Sacların Elektrik Direnç Nokta Kaynağında Kaynak Parametrelerinin Taguchi Yöntemiyle Optimizasyonu,” Düzce Üniversitesi Bilim ve Teknoloji Dergisi, 9, 702-711, (2021), DOI: 10.29130/dubited.837588
Published
2025-02-05
How to Cite
1.
Işik Şafak, Apay S, Özbek YY, Barlas Z, Ozsarac U, Aslanlar S. OPTIMIZATION OF WELDING PARAMETERS OF ELECTRICAL RESISTANCE SPOT WELDED 6082-7075 ALUMINIUM JOINTS USING THE TAGUCHI METHOD. MatTech [Internet]. 2025Feb.5 [cited 2025Mar.25];59(1):47–53. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1270
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