Aslam, Muhammad Hanzla  <br/><br/>
Orthogonal Optimization of Resistance Spot Welding (RSW) Parameters for Al 5052 with Al 3003 / 
Muhammad Hanzla Aslam 
 - 82p.  Soft Copy  30cm 
<br/><br/> The concept of light weight, fuel efficient, environmentally friendly and safety<br/>in automobile has raised the use of Aluminum alloys and their joining through<br/>resistance spot welding process for mass production. This study focuses on the<br/>orthogonal optimization of process parameters for Resistance Spot Welding (RSW) of<br/>Al 5052-H32 and AL 3003-0 hybrid structure in automobile / aerospace vehicles.<br/>Taguchi L9 orthogonal array was used to design the welding experiments. Welding<br/>current, welding time and electrode force are used as input parameters and maximum<br/>tensile shear strength (TSS) is used as output parameter. Welding parameters are<br/>optimized to achieve spot joint without expulsion and crack having suitable nugget size.<br/>Optical microscopy is used to study the nugget size through macrographs of the weld<br/>joint and microstructure of the nugget, HAZ and base material. Microhardness test and<br/>tensile shear test are performed to evaluate the strength and failure behavior of the weld<br/>joints. Maximum TSS achieved 91.7 MPa at 32 kA, 80 ms and 5.5 kN of welding<br/>current, welding time and electrode force respectively with button pull out failure.<br/>Taguchi L9 analysis gives optimized parameters as 34 kA welding current,<br/>80 ms welding time and 5.5 kN electrode force. ANOVA result shows that welding<br/>current has highest effect on weld tensile shear strength followed by welding electrode<br/>force and weld time. 
<br/><br/><label>Subjects--Topical Terms: </label><br/>MS Mechanical Engineering      
<br/><br/><label>Dewey Class. No.: </label>621