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Multi-Objective Optimization of Process Parameters in Resistance Spot Welding of A36 Mild Steel and Hot Dipped Galvanized Steel Sheets Using Non-dominated Sorting Genetic Algorithm

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Abstract

Industry is constantly moving towards an increasing of production speed while minimizing production costs. This paper presents an efficient method for minimizing production times and energies through optimization of process parameters in resistance spot welding (RSW). Two grades of steel were used in this study, ASTM A36 steel and A653 hot dipped galvanized steel. Welding was done in overlap configuration, grade for grade, while following complete factorial plans. Micrographic analysis revealed welds microstructure while micro-indentation hardness tests enabled to establish hardness profiles along weld nuggets. Tensile-shear tests have been carried out in order to quantify the mechanical strength of welds. Analysis of variance showed that welding current is the most significant parameter and contributes for about 70% to welds mechanical strength. The ratio of hardness in the fusion zone to nugget surface area was found to be correlated with the failure mode of welded specimens. On that basis, a multi-objective optimization of the process parameters, through the non-dominated sorting genetic algorithm was performed. This optimization resulted in a reduction of current, electrode pressing force and welding time of 10.58%, 13.59% and 32.61% respectively. Optimized parameters were then assessed trough tensile-shear testing of welded specimens, all specimens passed the validation tests by experiencing failure in the base metal.

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Authors and Affiliations

  1. Département de Mathématique, Informatique Et Génie, Université du Québec À Rimouski Rimouski, Québec, G56 3A1, Canada

    B. V. Feujofack Kemda & N. Barka

  2. Département de Génie Mécanique, École de technologie supérieure, Montréal, Québec, H3C 1K3, Canada

    M. Jahazi

  3. AMH Canada Ltée, Rimouski, Québec, G5L 1Z2, Canada

    D. Osmani

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  1. B. V. Feujofack Kemda
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  2. N. Barka
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  3. M. Jahazi
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  4. D. Osmani
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Correspondence to B. V. Feujofack Kemda.

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Feujofack Kemda, B.V., Barka, N., Jahazi, M. et al. Multi-Objective Optimization of Process Parameters in Resistance Spot Welding of A36 Mild Steel and Hot Dipped Galvanized Steel Sheets Using Non-dominated Sorting Genetic Algorithm. Met. Mater. Int. 28, 487–502 (2022). https://doi.org/10.1007/s12540-021-00986-9

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  • DOI: https://doi.org/10.1007/s12540-021-00986-9

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