| Summary: | The aim of this work was to investigate the effect of resistance spot welding (RSW) parameters on the quality of AA5451 joint with brass foil interlayer. Three welding parameters were used; welding current: 12750 and 13500 Amp, electrode pressure: 40 and 45 Bar, welding time: 1.2, 1.4 and 1.6 sec. The squeeze and hold time were kept constant with 1.98 sec for each case. A sheet of AA5451 of 1 mm thickness with brass foil (C26800) of 0.1 mm thickness as interlayer was used. A shear test was used to determine the sheer force of the welded specimen. The results of shear force were analyzed statistically using a Taguchi method with the aid of a Minitab program. The results indicated that the applied pressure and welding current decreased and increased the sheer force of joint respectively. Increasing the welding time decreased and increased the shear force for the intervals 1.2 – 1.4 and 1.4 – 1.6 sec respectively. The presence of the foil increased the shear force of joint by 16 %. The optimum values of parameters that found using the brass foil were; welding current: 13500Amp, electrode pressure: 40Bar, welding time: 1.6sec. A theoretical model of shear force as a function of welding parameters was derived.
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