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Tensile shear load in resistance spot welding of dissimilar metals: An optimization study using response surface methodology

Mechanical Engineering for Society and Industry · Vol. 3 No. 2 (2023) · pp. 66–77

DOI
10.31603/mesi.9606
ISSN
2798-5245
Published
2023-09-11
Publisher
Universitas Muhammadiyah Magelang
Language
en

Abstract

Resistance spot welding (RSW) is being applied extensively in different industries, specifically the automotive sector. Therefore, this study was conducted to optimize the tensile strength load (TSL) in RSW by investigating the application of dissimilar materials as input parameters. The optimization process involved the combination of different galvanized and non-galvanized steel materials. The production of car bodies using galvanized steel with approximately 13.0 microns thick zinc (Zn) coating was found to be a standard practice, but this zinc layer usually presents challenges due to the poor weldability. This study prepared 27 units of TSL samples using a spot-welding machine and a pressure force system (PFS) for the electrode tip. The aim was to determine the optimal TSL through the exploration of specified RSW parameters. The process focused on using the response surface methodology (RSM) to achieve the desired outcome while the Box-Behnken design was applied to determine the input parameters. The optimal TSL obtained was 5265.15 N by setting the squeeze time to 21.0 cycles at a welding current of 24.5 kA, a welding time of 0.5 s, and a holding time of 15.0 cycles. The highest TSL value recorded was 5937.94 N at 21.0 cycles, 27.0 kA, 0.6 s, and 15.0 cycles respectively. These findings were considered significant to the enhancement of productivity across industries, specifically in the RSW process. However, further study was required to investigate additional response variables such as the changes in hardness and microstructure.

Keywords

Collaboration network of the authors

40 authors · 115 co-authorship links · 1 across different organisations · showing the 40 most connected

Hover or tap a name to highlight its co-authors. Double-click to open the author's page.

  • Universitas Halu Oleo
  • University of Mataram
  • International Islamic University, Islamabad
  • Sam Ratulangi University
  • Affiliation unknown
  • Different organisations
  • Same organisation
  • Affiliation unknown
  • Thicker line = more joint articles · bigger circle = more articles
Show as table
Co-authorOrganisationJoint articles
Wega TrisunaryantiAffiliation unknown11
Khoirudin khoirudinAffiliation unknown8
Yuli Prasetyo AdhiAffiliation unknown5
Muhyidin MuhyidinUniversity of Mataram4
Amri AbdulahAffiliation unknown4
Nana RahdianaAffiliation unknown4
Muhamad Taufik UlhakimAffiliation unknown4
Tomas IrfaniAffiliation unknown4
Afif HakimAffiliation unknown4
Apang Djafar ShieddiequeAffiliation unknown3
Dyah Ayu FatmawatiAffiliation unknown3
Rachmat Abdul GaniAffiliation unknown3
Nur RahmawatiAffiliation unknown2
Choirul AnwarInternational Islamic University, Islamabad2
Dede Ardi RajabAffiliation unknown2
Yulfian AminandaAffiliation unknown2
Cahyarani ParamestiAffiliation unknown2
Savitri LarasatiAffiliation unknown2
Nugroho Raka SantosoAffiliation unknown2
Endah SuarsihAffiliation unknown2
Suwardi SuwardiAffiliation unknown2
Septa PrimanandaAffiliation unknown2
Herry WirianataAffiliation unknown2
Yiyi SulaemanAffiliation unknown2
Edi YatnoAffiliation unknown2
Jahidin JahidinUniversitas Halu Oleo1
Al RubaiynUniversitas Halu Oleo1
Safilu SafiluAffiliation unknown1
Muhammad YurisAffiliation unknown1
Muhammad AmirAffiliation unknown1
Muhammad Hasan BasriSam Ratulangi University1
Muarifuddin MuarifuddinAffiliation unknown1

Affiliations come from OpenAlex; journal OAI-PMH metadata carries none. Authors without an OpenAlex ID are matched by name, which can merge or split people.

Metadata source: OAI-PMH (metadata jurnal) https://journal.unimma.ac.id/index.php/mesi/oai, first harvested 9 Nov 2026, last seen 9 Nov 2026.
Original metadata (oai_dc) 
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	<dc:title xml:lang="en">Tensile shear load in resistance spot welding of dissimilar metals: An optimization study using response surface methodology</dc:title>
	<dc:creator xml:lang="en">Sukarman, Sukarman</dc:creator>
	<dc:creator xml:lang="en">Triyono, Triyono</dc:creator>
	<dc:creator xml:lang="en">Kristiawan, Budi</dc:creator>
	<dc:creator xml:lang="en">Amir, Amir</dc:creator>
	<dc:creator xml:lang="en">Fazrin, Nazar</dc:creator>
	<dc:creator xml:lang="en">Suhara, Ade</dc:creator>
	<dc:creator xml:lang="en">Azizah, Renata Lintang</dc:creator>
	<dc:creator xml:lang="en">Mucharom, Fajar</dc:creator>
	<dc:subject xml:lang="en">Box-Behnken design</dc:subject>
	<dc:subject xml:lang="en">Resistance spot welding</dc:subject>
	<dc:subject xml:lang="en">Response Surface Methodology</dc:subject>
	<dc:subject xml:lang="en">Tensile shear load</dc:subject>
	<dc:description xml:lang="en">Resistance spot welding (RSW) is being applied extensively in different industries, specifically the automotive sector. Therefore, this study was conducted to optimize the tensile strength load (TSL) in RSW by investigating the application of dissimilar materials as input parameters. The optimization process involved the combination of different galvanized and non-galvanized steel materials. The production of car bodies using galvanized steel with approximately 13.0 microns thick zinc (Zn) coating was found to be a standard practice, but this zinc layer usually presents challenges due to the poor weldability. This study prepared 27 units of TSL samples using a spot-welding machine and a pressure force system (PFS) for the electrode tip. The aim was to determine the optimal TSL through the exploration of specified RSW parameters. The process focused on using the response surface methodology (RSM) to achieve the desired outcome while the Box-Behnken design was applied to determine the input parameters. The optimal TSL obtained was 5265.15 N by setting the squeeze time to 21.0 cycles at a welding current of 24.5 kA, a welding time of 0.5 s, and a holding time of 15.0 cycles. The highest TSL value recorded was 5937.94 N at 21.0 cycles, 27.0 kA, 0.6 s, and 15.0 cycles respectively. These findings were considered significant to the enhancement of productivity across industries, specifically in the RSW process. However, further study was required to investigate additional response variables such as the changes in hardness and microstructure.</dc:description>
	<dc:publisher xml:lang="en">Universitas Muhammadiyah Magelang</dc:publisher>
	<dc:date>2023-09-11</dc:date>
	<dc:type>info:eu-repo/semantics/article</dc:type>
	<dc:type>info:eu-repo/semantics/publishedVersion</dc:type>
	<dc:format>application/pdf</dc:format>
	<dc:identifier>https://journal.unimma.ac.id/mesi/article/view/9606</dc:identifier>
	<dc:identifier>10.31603/mesi.9606</dc:identifier>
	<dc:source xml:lang="en">Mechanical Engineering for Society and Industry; Vol. 3 No. 2 (2023); 66-77</dc:source>
	<dc:source>2798-5245</dc:source>
	<dc:language>en</dc:language>
	<dc:relation>https://journal.unimma.ac.id/mesi/article/view/9606/4576</dc:relation>
	<dc:rights xml:lang="en">Copyright (c) 2023 Sukarman - Sukarman, Triyono Triyono, Budi Kristiawan, Amir Amir, Nazar Fazrin, Ade Suhara, Renata Lintang Azizah, Fajar Mucharom</dc:rights>
</oai_dc:dc>