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Statistical Investigation of Resistance Spot Welding Quality Using a Two-Stage, Sliding-Level Experiment


 Quality variation in resistance spot welding is a major concern in the automotive industry. This paper investigates the weld quality using a newly developed two-sage, sliding-level experiment. Welding current is treated as a “slid factor” and is determined based on the settings of other process variables. Engineering knowledge is applied in statistical model selection. From the analysis, it is found that abnormal process conditions, including axial misalignment, angular misalignment, poor fitup, edge weld, and electrode wear, significantly affect the size of the welds, and thus cause large variations on the weld quality. Although they may help increase the weld size, these abnormal process conditions generally lead to a less robust welding process. Developed initially for this study, the new experimental design and analysis procedures are believed to be generic and can be applied to other processes.