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Statistical modeling and optimization of the resistance welding process with simultaneous expulsion magnitude consideration for high-strength low alloy steel

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Abstract

In this investigation, the regression analysis together with the desirability function approach was involved to optimize the resistance welding parameters for the high-strength steel HSLA 420. The Box-Behnken experimental design (BBD) was employed for the control factors of welding time, welding current, and electrode pressure. The values of nugget diameter, ultimate peak load, maximum displacement, and absorption energy were identified and processed using the approach of multiple-objective optimization based on ratio analysis (MOORA). The weight loss of the base metal before and after welding was measured and computed to estimate the welding expulsion magnitude. The calculated statistical parameters displayed that the welding current had the most momentous influence on the welding quality and welding expulsion. The welding joints free of expulsion with sufficient mechanical properties can be achieved at the welding current of 8.4 kA, electrode pressure of 0.5 MPa, and welding time of 13 cycles.

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Funding

The authors are grateful for the financial support provided by the Natural Science Foundation of Shandong Province (ZR2016EEM47/ZR2018PEE004) and open projects of State Key Laboratory for Strength and Vibration of Mechanical Structures (SV2019-KF-39).

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Authors and Affiliations

  1. Department of Welding Engineering, Institution of Engineering and Technology, South Ural State University, Chelyabinsk, 454080, Russia

    Dawei Zhao, Alexander Osipov & Nikita Vdonin

  2. State Key Laboratory for Strength and Vibration of Mechanical Structures, Xi’an Jiaotong University, Xi’an, 710054, China

    Dawei Zhao

  3. Aerospace Department, Institution of Engineering and Technology, South Ural State University, Chelyabinsk, 454080, Russia

    Alexander Bezmelnitsyn

  4. Guangxi Zhuang Autonomous Region Institute of Metrology and Test, Nanning, 530007, China

    Dongjie Liang

Authors
  1. Dawei Zhao
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  2. Alexander Osipov
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  3. Alexander Bezmelnitsyn
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  4. Nikita Vdonin
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  5. Dongjie Liang
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Corresponding authors

Correspondence to Dawei Zhao or Alexander Osipov.

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The authors declare no competing interests.

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The results in this article can be replicated via software such as Minitab, MODDE, and Design Expert. The ABC algorithm can be operated using the software Matlab.

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Zhao, D., Osipov, A., Bezmelnitsyn, A. et al. Statistical modeling and optimization of the resistance welding process with simultaneous expulsion magnitude consideration for high-strength low alloy steel. Int J Adv Manuf Technol 113, 1173–1189 (2021). https://doi.org/10.1007/s00170-021-06696-1

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  • DOI: https://doi.org/10.1007/s00170-021-06696-1

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