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Resistance spot-welding (RSW) is a non-solid-state welding process that is significantly utilized in the self-propelled industry for manufacturing motorized bodies and parts. In this study, current and voltage data were recorded with the help of Miyachi Weld Checker for determining the variation of dynamic resistance over a welding process. Variation in dynamic resistance was analyzed for characterizing the nugget growth. The dynamic contact resistance (DCR) curves delineate that the entire process of nugget progression is composed of contaminants breakdown, asperity softening, resistance increment, growing stage, and stable stage. Further, tensile-shear test and fatigue test were performed for determining peak load and energy absorption, and dynamic behavior of spot-welded samples. Two-parameter Weibull distribution was utilized for statistical analysis of the fatigue test results of the spot-welded joint.

Fatigue life assessment of dissimilar thickness resistance spot welded C-Mn steel using Weibull distribution