Recent Status of Research and Developments in Resistance Spot Welding

International Journal of Mechanical Engineering

© 2025 by SSRG - IJME Journal

Volume 12 Issue 3

Year of Publication : 2025

Authors : Ramakant Choudhari, Amit Adhaye, Vishal Sulakhe, Ritesh Fegade

10.14445/23488360/IJME-V12I3P101

How to Cite?

Ramakant Choudhari, Amit Adhaye, Vishal Sulakhe, Ritesh Fegade, "Recent Status of Research and Developments in Resistance Spot Welding," SSRG International Journal of Mechanical Engineering, vol. 12,  no. 3, pp. 1-27, 2025. Crossref, https://doi.org/10.14445/23488360/IJME-V12I3P101

Abstract:

Resistance Spot Welding (RSW) continues to be a cornerstone of modern manufacturing, predominantly in the automobile industry. This comprehensive review examines recent advancements in RSW technology, focusing on recent developments in RSW. Integrating advanced materials, such as cutting-edge High-Strength Steel (HSS) and lightweight alloys, has necessitated significant innovations in welding processes and quality control. This review critically analyzes progress in joining dissimilar materials, optimizing process parameters, and understanding complex microstructural evolution in weld zones. Emerging technologies, including machine learning-based predictive models and real-time monitoring systems, are reshaping quality assurance in RSW. By synthesizing findings from over 100 recent studies, this article provides a holistic view of the current state of RSW technology and identifies key areas for future research. The ongoing evolution of RSW underscores its enduring relevance in an era of rapid technological change and increasingly demanding manufacturing requirements.

Keywords:

Resistance Spot Welding (RSW), Dissimilar materials joining, Process optimization, Process parameters, Microstructure, High-strength steels, Hybrid joints.

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