Resistance Spot Welding of Dissimilar Metals (AISI 1005 and AISI 304L): Experimental and Numerical Investigation of Tensile-Shear and Vibration Loads

Osamah Sabah Barrak; Hadhami Ben Slama; Slim Ben-Elechi; Sami Chatti

doi:10.51173/jt.v7i4.2776

Authors

Osamah Sabah Barrak National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia https://orcid.org/0000-0002-0533-6561
Hadhami Ben Slama National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia
Slim Ben-Elechi National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia
Sami Chatti National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia

DOI:

https://doi.org/10.51173/jt.v7i4.2776

Keywords:

Vibration Analysis, Eigenfrequency, Finite Element Analysis (FEA), Resistance Spot Welding (RSW), Sustainable Manufacturing

Abstract

This study investigates the resistance spot welding (RSW) of two different steels, AISI 1005 and AISI 304L, using both experiments and computer simulations. Researchers used a Taguchi L16 design to test how welding current, squeeze time, welding time, and hold time affect tensile-shear strength (TSF). The best welding setup reached a TSF of 78.86 MPa, while the lowest settings gave 44.31 MPa. Simulations in COMSOL Multiphysics modeled the thermal, electrical, and mechanical behavior of the welds. The predicted TSF values matched the experiments closely, with less than 5% difference. Free-vibration modal analysis was also done for cantilever and fixed-fixed setups. The experimental and simulated eigenfrequencies were similar, with errors within ±3%, supporting the accuracy of the model. These results show that choosing the right RSW parameters can greatly improve both the strength and stiffness of AISI 1005/AISI 304L joints.

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Author Biographies

Osamah Sabah Barrak, National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia

Hadhami Ben Slama, National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia

Slim Ben-Elechi, National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia

Sami Chatti, National Engineering School of Monastir, University of Monastir, LGM, ENIM, Avenue Ibn-Eljazzar, 5019 Monastir, Tunisia

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