Process Optimization of Spot Welding for Galvanized Automotive Steel Sheets

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    Shrikrushna Balasaheb Bhosale,

  • Amarjit Prakashrao Kene,

  1. Associate Professor, Department of Mechanical Engineering, SVERI’s College of Engineering, Pandharpur, Maharshtra, India
  2. Associate Professor, Department of Mechanical Engineering, Dr. D. Y. Patil Institute of Technology, Pimpri, Pune, Maharshtra, India

Abstract

Resistance Spot Welding (RSW) is a pillar of the modern automotive industry with the usage of lightweight and high-strength products at the highest point of demand. The optimum weld quality of galvanized steel sheets which is a material of choice because of its additional corrosion protective property is however not achieved easily. This study is a well-developed data-based solution to designing the RSW process in the most efficient way, providing increased joint strength, structural soundness, and cost-effectiveness.  An orthogonal array is used (L27) to perform a thorough experimental analysis of the impact of essential parameters such as the number of weld spots, the specimen and weld distance, the current, force, and the electrode using the SPSS program to determine the critical welding parameters. Knowledge of joints Using advanced mechanical testing such as tensile shear tests as well as cross-tension on precision-engineered fixtures gives definitive evaluations of how joints perform. Regression analysis is taken into use in order to come up with a good predictive model since the measured deviation between experimental and predicted tensile shear strength is low at 0.57%, which shows that the model is not erratic. In addition to the signal-to-noise ratio technique, the Taguchi approach to experimental design and analysis of variance (ANOVA) finds the optimal settings.

Keywords: Welding current, Quantity of spots, Distance between spots, Tensile and Shear strength, Taguchi method, Regression analysis, Optimization technique.

How to cite this article:
Shrikrushna Balasaheb Bhosale, Amarjit Prakashrao Kene. Process Optimization of Spot Welding for Galvanized Automotive Steel Sheets. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
Shrikrushna Balasaheb Bhosale, Amarjit Prakashrao Kene. Process Optimization of Spot Welding for Galvanized Automotive Steel Sheets. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239329


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Ahead of Print Subscription Original Research
Volume 14
02
Received 21/08/2025
Accepted 27/10/2025
Published 28/03/2026
Publication Time 219 Days
56

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