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Resistance spot welding is a leading joining method in thin structures made of
structural steel grade S235JR samples, the heart of automotive bodies. On average, there
are nearly 5000 resistance spot welds in steel body-in-white. The main welding parameters
significantly influencing spot weld quality are welding current and welding time. Varying
this parameter can greatly improve the spot weld strength and visual appearance and
reduce production costs. This research aims to determine the optimal set of RSW
(resistance spot welding) parameters for similar low-carbon steel joints. Experiments were
conducted on steel sheets joined using various welding times, joining pressures, and
current settings. Samples were then evaluated through visual inspection, tensile-shear
testing, nugget size, and heat-affected zone measurement. Additionally, a metallographic
microstructure examination on the joint cross-sections was conducted for specified
samples, and Vickers hardness of samples was measured to analyse the effect of RSW
parameters comparatively. The optimal set of welding parameters for high-quality RSW
was successfully obtained. The joints ' process parameters and mechanical properties were
investigated using artificial intelligence methods to establish the optimal resistance spot
welding parameters.
