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<p>The present study investigates the resistance spot welding (RSW) behaviour of HSLA 355 steel with the objective of identifying and optimizing the critical parameters governing tensile shear strength (TSS) in shock absorber bracket. Recurring weld failures observed in a production part motivated a systematic evaluation using Response Surface Methodology (RSM) with a Box–Behnken Design (BBD). A total of 46 specimen was produced by varying welding current, squeeze time, hold time, weld time, and electrode pressure across three levels. TSS was measured. ANOVA results confirmed that welding current was the most influential factor, followed by weld time and electrode pressure, with significant quadratic and interaction effects indicating strong non-linear thermal mechanical coupling. The developed quadratic model exhibited excellent predictive accuracy (R<sup>2</sup> ≈ 0.99). Numerical desirability optimization identified an optimal process window 10&#xa0;kA current, 30&#xa0;ms squeeze time, 18&#xa0;ms hold time, 20&#xa0;ms weld time, and 3.5&#xa0;bar pressure yielding a predicted TSS of 554&#xa0;MPa with a composite desirability of 1.000. Confirmatory tests validated a 15–22% strength improvement and reduced variability relative to the existing production parameters. Microstructural analysis of optimized samples revealed uniform nugget formation, balanced indentation, and consistent pull-out failure modes, confirming sound metallurgical bonding. The optimized parameter set directly addresses recurring field failures and establishes a robust, industry-ready welding window for HSLA 355 components in automotive applications.</p> Graphical abstract <p></p>

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Mitigating weld failures through microstructure-based optimization of resistance spot welding parameters in HSLA 355 automotive components

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • R. M. Choudhari,
  • Amit Adhaye

摘要

The present study investigates the resistance spot welding (RSW) behaviour of HSLA 355 steel with the objective of identifying and optimizing the critical parameters governing tensile shear strength (TSS) in shock absorber bracket. Recurring weld failures observed in a production part motivated a systematic evaluation using Response Surface Methodology (RSM) with a Box–Behnken Design (BBD). A total of 46 specimen was produced by varying welding current, squeeze time, hold time, weld time, and electrode pressure across three levels. TSS was measured. ANOVA results confirmed that welding current was the most influential factor, followed by weld time and electrode pressure, with significant quadratic and interaction effects indicating strong non-linear thermal mechanical coupling. The developed quadratic model exhibited excellent predictive accuracy (R2 ≈ 0.99). Numerical desirability optimization identified an optimal process window 10 kA current, 30 ms squeeze time, 18 ms hold time, 20 ms weld time, and 3.5 bar pressure yielding a predicted TSS of 554 MPa with a composite desirability of 1.000. Confirmatory tests validated a 15–22% strength improvement and reduced variability relative to the existing production parameters. Microstructural analysis of optimized samples revealed uniform nugget formation, balanced indentation, and consistent pull-out failure modes, confirming sound metallurgical bonding. The optimized parameter set directly addresses recurring field failures and establishes a robust, industry-ready welding window for HSLA 355 components in automotive applications.

Graphical abstract