Abstract
This paper investigates the choice of input process variables that create acceptable welds in the resistance spot welding of galvanized steel sheets. The effects created by the interactions between the process variables in terms of the size of the weld nugget, tensile-shear strength, and peel strength are also investigated. Regression equations are obtained and their ability to predict the size of the weld nugget, tensile-shear strength, and peel strength is tested in a series of test cases. The obtained data is then used in response optimization studies. The predicted optimized input process variables were experimentally verified by comparing measured and predicted optimized target responses. The methodology adopted in the present investigation is shown to be able to model, predict, and response optimize the input process variables for resistance spot welding of galvanized steel sheets.