Resistance spot welding process (RSW) is one of important manufacturing processes in automotive industry for assembling bodies. Quality and strength of the welds and therefore body mainly are defined by quality of the weld nuggets. Resistance Spot Welding (RSW) is widely used for its low cost, high speed, simple mechanism and applicability for automation. It depends on the resistance of the base metal and the amount of current flowing to produce the heat necessary to make the spot weld. There

more »

... e various process parameters (weld current, weld time, electrode force) which affect the weld nugget and its strength. So it is necessary to optimize the process parameters of resistance spot welding process. Therefore it is very important to understand the behaviour of spot welds and their failure characteristics. This paper focus on response surface method to optimize the machining parameter of resistance spot welding that is (weld current, weld time, electrode force) which are responsible for Nugget diameter & strength of the weld. The experimental studies have been conducted under varying welding current & welding time, electrode force.