Abstract
Resistance spot welding process (RSW) appeared widely applicable in various industries, especially for mass production. The typical applications of this process are in automobile industries, furniture, and other sheet metal industries. Resistance spot welding has been considered a successful process for welding ferrous based metal sheets. RSW process has some difficulty in welding aluminum and its alloys. Generally, aluminum alloys produce bad welds because of their physical and metallurgical properties like oxide formation, thermal expansion, thermal contraction, less weldability, and formation of IMC's. The present study targets the feasibility evaluation and mechanical characterization of RSW welds on AA5083alluminum alloys. Optimum input process parameters were identified for welding of 2.5 mm thick Al sheets, and three output variables were analyzed, i.e., Tensile strength, joint hardness, and nugget diameter. It was observed that joint strength was significantly improved by increasing the process parameters. The fair welds with 227kN tensile strength were produced at the parameters3000N electrode pressure, welding current 8KA and 15 weld cycle time. These input parameters also gave the moderate diameter of the nugget, which is equal to 7.61 mm and low(preferable) average hardness in the nugget, i.e., 101Hv. The weld nugget diameter has a significant effect on the process parameter. It has been seen that the increase in process parameters, i.e., weld cycle time, the pressure of the electrode and welding current, results in the increment in weld nugget size. The maximum sizes of the nugget diameter and weld strength were observed with sample number 9, which is 7.94 mm and 231kN. The strength of the welds is significantly low compared with the base metal. However, it has been observed that the welding of 2.5 mm thick AA5083 aluminum sheets by RSW is possible and might be acceptable for lightweight applications.
(c) 2021 Elsevier Ltd. All rights reserved. Second International Conference on Aspects of Materials Science and Engineering (ICAMSE 2021).