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The prediction of weld nugget diameter has been a primary objective in the development of resistance spot welding monitoring techniques. The prediction algorithms must be able to work with the wide range of process variations commonly encountered in a production environment. Welding experiments simulating process variations were conducted on AA5754 sheet with structural adhesive using AC welding equipment. The parameters and simulated production conditions were extremely wide ranging, and included welding sections of actual car components. Results from the work have demonstrated that by using suitable electrical signals sampled from the process, robust models can be designed that are capable of making good diameter predictions under a wide range of welding conditions.

Weld bonding of aluminium autobody structures offers automotive vehicle manufacturers the opportunity of achieving significant weight reduction, compared to equivalent steel structures. Further, this is achievable using volume production manufacturing methods. This paper considers all key aspects of the weld bonding process, in particular the equipment requirements and the factors that are important in reliably achieving satisfactory structures. Methods of minimising damage to the adhesive bondline and assessment of spot weld quality are discussed. Using experience gained from extensive weld bonding trials, suitable parameters for robust weld bonding are recommended.