Experimental Study an improvement of Parameters Affecting Resistance Spot Welding Strength in Halogen lamps by Taguchi Statistical Method

The Resistance Spot Welding (RSW) has lots of industrial application, especially for body construction and some parts like car lamps. The aim of this research was optimizing of the production line efficiency and improving the welding strength of the car lamps. Experimental studies were conducted on the factors affecting the weld strength in a H4 halogen lamp (wing to body connection). The experiments design and results analysis were done by Taguchi method and Minitab software. Welding current, welding time and electrode material were studied as main factors (inputs) in the actual lamp samples. Experimental results and statistical analyzes indicated that the high dependence of welding strength on welding time is primarily and with a quantitative difference in the second order to the welding current. According to the results, it was found that with any kind of electrode material, if welding time and welding current increases to moderate, welding strength will be improved. But in high values of time and current, there is a negative effect on the welding strength. Although the welding electrode has the third highest rating on weld strength. But during the testing process and analyzing it was found that the efficiency of the lamp production line in the case of using tungsten electrodes in the significant amount of 29.17% compared to the electrodes of Copper is more. While the welding strength of the tungsten electrode is only 5.5% lower than the copper electrode. This strength is still within allowed and acceptable limits of the relevant standards.