Best practice is primarily based on nugget penetrations into the thin sheet. Penetration results were dominated by electrode considerations. Influence of electrode variations is consistent with previous work. Electrode variations cannot be considered a solution in an automotive environment. Penetrations into the thin sheet on the order of 50% could be achieved using the developed baseline conditions. Indentations of less than 0.5 mm were observed at baseline conditions. Joint strengths were not strongly affected by process (or electrode) variations. MFDC electric servo-guns appear to offer advantages for RSW complex (thin/thick/thick) stack-ups.
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