Process Parameter Selection for Resistance Spot Welding through Thermal Analysis of 2 mm CRCA Sheets

An attempt is made to arrive at suitable process parameters for resistance spot welding through thermal analysis. 2 mm Closed Rolled Closed Anealing (CRCA) sheet metal is selected as work piece. Nugget and electrode diameter are evaluated from emperical relations. Full factorial Design Of Experiment (DOE) is applied for weld current and time. Thermal analysis is carried out for selected DOE values using SYSweld. Temperature distribution, nugget and Heat Affected Zone dimensions are obtained from the analysis. Weld strenght is analysed through experimental trails. Optimum process parameter for spot welding of 2 mm CRCA sheet is arrived by comparing simulation and experimental results.