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In industry develop mechanized and automated welding processes, the welding field taken a high place with raising demand for high production rates, quality, and high precision. Some problem faces resistance spot welding of carbon steel such as selecting suitable and optimum parameters of input process that control conditions, which help to gain requirement nugget quality or predicting the nugget quality.
Mathematical models have been developed by (expert design program 7.1) utilizing the response surface methodology for the resistance spot welding of 2 mm thickness of carbon steel workpiece to relate important process control parameters like (welding current, electrode force as well as welding time) to an important nugget quality parameter. With utilize the response surface method to predict and optimizing the weld nugget volume in resistance spot welding of carbon steel. The weld nugget has been measured and finding out the effect of force and current on electrode penetrant depth (a). The study finding shown that the response surface methodology can be employed easily for developing mathematical models for predicting weld bead geometry within the workable region of process parameters.