Optimization of the Process Parameters in Resistance Spot Welding of IS410:2006 Grade CuZn40 Brass Material Using Taguchi Method

Resistance spot welding process is widely used in industry for sheet joining purposes such as Automobile, Aerospace Industry. The problems associated with resistance spot welding are tendency of alloying with the electrode resulting in increased wear of copper electrodes and subsequent deterioration of weld quality. More current and time lead to expulsion and overheating of the electrode affects the quality of the weld and less value result in insufficient weld strength. The complex behaviour of this process must be analysed to set the optimum parameters to obtain robustness in the weld quality. The experimentation carried under varying welding current, welding time, electrode force and hold time. Taguchi Design concept of L9 orthogonal array has been used to determine analysis of variance for determining most significant parameters affecting the spot weld performance. The experimental results confirmed the validity of used Taguchi Method for enhancing welding performance and optimizing the welding parameters in resistance spot welding process