Exploring Resistance Spot Welding of Similar Triple Thin Sheets

Resistance spot welding of two sheets of thickness greater than 0.75mm is often required in an industry. Sometimes lower than 0.75mm thickness of sheets are also needed to be joined. In this work, triple galvanized iron, triple 6061 aluminum alloy and triple AISI 430 stainless steel are spot welded separately and are explored in terms of weld strength. Weld current, weld time and electrode pressure are varied throughout the experiments to find out the weld strength for different sets of materials. Every set of experiments has two types of joint design and its weld strength in different interfaces is tested and nugget diameter is measured. High current is found to cause expulsions in case of the joint of aluminium alloy triple sheets although results are found to be good in case of similar triple sheet joint of the materials selected with appropriate process parameters.