OBRABOTKAMETALLOV Vol. 27 No. 3 2025 technology In conclusion, the RSW process is characterized by a complex interaction of multiple factors. However, the primary controllable parameters are welding current, electrode force, and welding period, all of which significantly affect the quality of the welded joint. Table 2 presents a summary of the influence of these parameters on the RSW process and weld quality, along with corresponding optimization measures based on a review of the literature [1–23]. Т a b l e 2 Recommendations for optimizing the basic parameters of contact spot welding Process variables Effect on the welding point Optimization measures Welding current Size and shape of the weld; Occurrence of expulsion; Shear and tensile strength form the microstructure of the weld It is necessary to use a process modeling and experimentation to find the optimal combination for a specific process Weld period Tensile strength, peeling, and shear strength of welded joints It is necessary to apply variation rather than a constant value during the process Electrode force Energy efficiency of the process; Occurrence of molten metal expulsion; Specific features of weld core solidification during spot welding It is necessary to apply variation rather than a constant value during the process TIn conclusion, it should be noted that achieving high-quality welds of aluminum alloys by resistance spot welding (RSW) requires careful selection of an optimal combination of welding cycle parameters. Specifically, to attain high shear tensile strength and welds with a large fusion zone diameter, it is essential to consider the potential occurrence of undesirable phenomena such as metal expulsion, spatter, cold welding, or formation of an insufficiently sized fusion zone. A review of the literature [1–23] indicates that welding current is the key parameter determining heat input during welding and is also the most easily adjustable parameter. Additionally, the application of variable electrode force, implemented via an electric servomechanism, can improve process stability and enhance weld quality [14–23]. Future research will focus on optimizing resistance spot welding parameters for aluminum alloys of various thicknesses. Conclusions 1. In resistance spot welding (RSW) of Al-5 Mg aluminum alloy, an increase in welding current and welding period leads to higher heat input and, consequently, an increase in the fusion zone diameter. The shear tensile strength of the welded joint also increases with rising welding current and welding period, which is attributed to the enlargement of the fusion zone diameter — a key factor determining joint strength. 2. For resistance spot welding (RSW) of 2.5 mm thick lap joints of Al-5 Mg aluminum alloy, the optimal parameters ensuring a shear tensile strength of 238 MPa are: electrode force of 3,000 N, welding current of 12 kA, and welding period of 25 ms. References 1. Kochergin K.A. Kontaktnaya svarka [Contact welding]. Leningrad, Mashinostroenie Publ., 1987. 240 p. 2. Orlov B.D. Tekhnologiya i oborudovanie kontaktnoi svarki [Technology and equipment of contact welding]. Moscow, Mashinostroenie Publ., 1986. 352 p. 3. Zhou K., Yao P. Overview of recent advances of process analysis and quality control in resistance spot welding. Mechanical Systems and Signal Processing, 2019, vol. 124, pp. 170–198, DOI: 10.1016/j.ymssp.2019.01.041. 4. Hao M., Osman K.A., Boomer D.R., Newton C.J. Developments in characterization of resistance spot welding of aluminum. Welding Journal – Including Welding Research Supplement, 1996, vol. 75 (1), pp. 1–4. Available at:
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