This paper presents the findings of a weidability study of drawn arc stud welding various advanced high-strength steels (AHHS) including Usibor, boron steel, and HC500C (DP 800) of various thicknesses and coatings from several automakers, and benchmarked against mild steel. M6 wide top (or large flange) stud is used in the study. Instead of poking for a 9-box weld lobe from trial-and-error, a robot is used to comb a 3D weld parameter space of arc current, arc time and lift height, with parameter grid of 380-1200 welds for each AHHS grade. A designed experiment approach maps out the relationship between DOE inputs of control variables, and DOE outputs of weld quality statistically. Objective and subjective weld quality are measured, including destructive conical bend for weld strength, dimple, sag, burn-through, head melting, cracking, excessive expulsion, and backside marking.
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