Welding of mild steel is one of the most common processes in spot welding. Numerous methods for ensuring high-quality welds are based on dynamic resistance. However, in general, these methods are only useful over a relatively narrow range of welding parameters. This article presents a universal quality assurance method based on dynamic resistance that is valid over a wide range of welding time, welding current, electrode force and electrode tip geometry (up to and including complete tip mushrooming). This method was constructed on the basis of models describing current density redistribution at the faying surface during the welding process. Validation of the method has been confirmed experimentally. The comparison of results shows that the method provides the maximum nugget size.
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