Modeling and optimization of resistance spot welded aluminum to Al-Si coated boron steel using response surface methodology and genetic algorithm

The modeling and optimization of resistance spot welded 5052 aluminum to Al-Si coated boron steel was quantitatively analyzed using response surface methodology and genetic algorithm. The significance and accuracy of the quadratic models was calculated by F tests, P tests, and R-2 tests. The welding current is the most parameter in affecting shear strength whereas all the three parameters have a significant influence in determining nugget diameter according to response surface analysis. After obtaining the optimized parameters of 26 kA, 7.66 kN, and 139.3 ms by genetic algorithm, the optimized sample exhibited a sound appearance without any visible defects and a better shear strength in excess of 5.8 kN. Another comparative experiment shows that the Al Si coating plays a significant role in improving the metallurgical bonding during the RSW of aluminum to steel.

Automated summary

The quantitative analysis of resistance spot welded 5052 aluminum to Al-Si coated boron steel was conducted using response surface methodology and genetic algorithm, optimizing parameters and verifying significance and accuracy. The optimized sample exhibited a sound appearance and improved shear strength, indicating the significant role of Al Si coating in RSW of aluminum to steel.