Prediction Using Regression Model For Tensile Shear Strength Of Resistance Spot Welding 5052 Aluminium Alloy Using Full Factorial Design Model

• Main Author: Redzuan, Faiz Zuhairy
• Format: Monograph
• Language: English
• Published: Universiti Sains Malaysia 2017
• Subjects: T Technology; TA401-492 Materials of engineering and construction. Mechanics of materials
• Online Access: http://eprints.usm.my/52754/1/Prediction%20Using%20Regression%20Model%20For%20Tensile%20Shear%20Strength%20Of%20Resistance%20Spot%20Welding%205052%20Aluminium%20Alloy%20Using%20Full%20Factorial%20Design%20Model_Faiz%20Zuhairy%20Redzuan_B1_2017.pdf; http://eprints.usm.my/52754/

Coraza Systems Malaysia Sdn. Bhd. is a sheet metal company which produce sheet metal products such as aerospace part, electrical part and home appliance. There was a problem on strength of weld joint of 5052 aluminium alloy product which was assembled by RSW process. This project was conducted to study on the significant factor and to find the best interaction between resistance spot welding (RSW) parameters. The welding process parameters involved are weld current, in kA (20.0, 18.2, 16.3), weld time, in ms (0.2475, 0.2250, 0.2025) and weld pressure, in bar (1.144, 1.040, 0.936). Full factorial design (FFD) was employed for the development of design matrix for this research. 11 experiments were conducted based on the designed matrix. Analysis of variance (ANOVA) technique was applied to obtain the most significant factors and their interaction effect on tensile shear strength based on the P-value of the factors. The most significant factor found for RSW process was weld current with 0.003 probability value which was lower than 0.05. The linear-square model developed using ANOVA was Y= 209.018 -11.9395 C + 95.5389 T -291.238 P + 17.8590 CP. The coefficient of determination R2 calculated was 91.13% which the value indicated that the compatibility of the model to the experimental result. The highest tensile shear test obtained from the experiment was 63.61 MPa which was higher compared to the typical used parameters at Coraza for 5052 aluminium alloy with tensile strength only 41.05MPa. The FFD employed in this project proved to be an effective tool to find the significant factors of RSW process which contribute to the tensile shear strength of 5052 aluminium alloy.