Process Parameter Optimization of Resistance Spot Welding for AMS 4902 Titanium Grade 2 Sheet Metal

International Journal of Mechanical Engineering

© 2024 by SSRG - IJME Journal

Volume 11 Issue 10

Year of Publication : 2024

Authors : Anishkumar H. Gandhi, Prashant Hasmukhray Solanki

10.14445/23488360/IJME-V11I10P106

How to Cite?

Anishkumar H. Gandhi, Prashant Hasmukhray Solanki, "Process Parameter Optimization of Resistance Spot Welding for AMS 4902 Titanium Grade 2 Sheet Metal," SSRG International Journal of Mechanical Engineering, vol. 11,  no. 10, pp. 61-73, 2024. Crossref, https://doi.org/10.14445/23488360/IJME-V11I10P106

Abstract:

One method frequently used in the aerospace industry to join sheet metal is resistance spot welding or RSW. This RSW technique works especially well for lap joining thin titanium sheets when joint access is restricted. However, overheating and insufficient nugget formation during RSW makes it difficult to obtain strong welds on pure titanium sheets. Therefore, in order to achieve optimal tensile strength during the RSW process, the parameters such as electrode force, weld current, and weld time were optimized in this study. The experiments were conducted on 1 mm thick AMS 4902 grade 2 titanium metal sheets as per the full factorial Design of the Experiment (DoE). Then, those experiments were verified for defect-free welding with the help of Non-Destructive Testing (NDT) methods. Later, the microstructural analyses showed adequate grain structures on the nugget region. Ultimately, the welding parameters were fine-tuned to align with the goal of maximizing tensile load. This means that the best RSW parameter for achieving a maximum tensile load of 8397.04N at 0.9989 desirability is 10kA current, 40 cycle time, and 6000N electrode force. The optimized solution was confirmed through experimentation, with only a 0.04% margin of error detected. Hence, the proposed DoE and optimization technique may be helpful for aerospace industries while optimizing RSW parameters for a desired tensile load.

Keywords:

Resistance spot welding, Dye penetration, Tensile load, Titanium, Full factorial design.

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