Abstract: This paper investigates the development of weld zone
in Resistance Spot Welding (RSW) which focuses on weld nugget and Heat Affected Zone (HAZ). The effects of four factors namely
weld current, weld time, electrode force and hold time were studied using a general 24 factorial design augmented by five centre points. The results of the analysis showed that all selected factors except
hold time exhibit significant effect on weld nugget radius and HAZ size. Optimization of the welding parameters (weld current, weld
time and electrode force) to normalize weld nugget and to minimize
HAZ size was then conducted using Central Composite Design (CCD) in Response Surface Methodology (RSM) and the optimum
parameters were determined. A regression model for radius of weld nugget and HAZ size was developed and its adequacy was evaluated.
The experimental results obtained under optimum operating conditions were then compared with the predicted values and were
found to agree satisfactorily with each other