Abstract
Joining sheet metals using the spot welding process is the most economical
and commonly employed method by the manufacturing industries in producing
automotive and aerospace components. This research analyzes the joining of stainless
steel of grade EN 1.4301 (AISI 304) welded with EN 1.4435 (AISI 316L) in the cross
tension configuration. Four different process parameters, electric current, contact
pressure, heating, and squeezing time, are analyzed in the present study. The integrity
of the cross lap joints is evaluated by cross tension failure tests and metallurgical
analysis. The results are evaluated, and optimal process parameters are obtained by
design expert software. A confirmation test is carried out to verify the optimum
parameters. It has been found that the electric current is the most influential factor, and
a maximum of 14.85 kN cross tension failure load is obtained. The mathematical model
developed using the response surface methodology (RSM) has an R2 value of 95.03%,
compared with the results of the multilayered ANN model with four neurons in the
interface layer. ANN proved to be a slightly better model with an R2 value of 97.6%.
Keywords: ANN, ANOVA, Cross tension strength, Dissimilar sheets, RSW, Stainless steel.