Probing the Effect of Pre- and Post-heating in Resistance Spot Welded Multi-material TWB system through Response Surface Methodology

Probing the Effect of Pre- and Post-heating in Resistance Spot Welded Multi-material TWB system through Response Surface Methodology | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Probing the Effect of Pre- and Post-heating in Resistance Spot Welded Multi-material TWB system through Response Surface Methodology Anand Kumar Mandal, Rakesh Kumar, Bikash Kumar, Deepika Rani This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5444183/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 01 Aug, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract This study investigates the optimization of the resistance spot welding (RSW) process in a three-sheet, multi-material configuration, utilizing steel alloys of varying thicknesses, namely, AISI 1035 (1.2 mm), ASTM A36 (2.0 mm), and IFHS 350 (2.5 mm). Advanced pulse modulation schemes, including single pulse (welding cycle), double pulse (preheating + welding and welding + post-heating cycle), and triple pulse (preheating + welding + post-heating cycle), were systematically analyzed. Response Surface Methodology (RSM) was employed to predict key weld outcomes, i.e., weld nugget diameter, elongation, and failure load; validated via Analysis of Variance (ANOVA). Microstructural analysis through Electron Backscatter Diffraction (EBSD) focused on kernel average misorientation (KAM) and grey-scale image quality (IQ) mapping to assess lattice distortion, dislocation density, and internal stresses. Results indicated that double pulse (welding + post-heating) and triple pulse cycle induce high dislocation density (~ 250–300 × 10¹² m⁻²) and non-diffusional martensitic transformation, leading to significant brittleness, reduced elongation, and failure load. In contrast, optimized preheating in the double pulse cycle (preheating + welding) increased weld nugget diameter from ~.5 → 10 mm, joint failure load from ~15 → 19.5 kN, and elongation from ~9 to 12.5 mm. This work provides critical insights into RSW process behaviour for multi-material, multi-thickness configurations, advancing the understanding of high-performance applications in complex welded structures. Resistance spot welding Tailor Welded Blank (TWB) Response Surface Methodology (RSM) Analysis of Variance (ANOVA) Electron Back-Scatter Diffraction (EBSD) analysis Desirability function Full Text Cite Share Download PDF Status: Published Journal Publication published 01 Aug, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 03 Feb, 2025 Reviewers agreed at journal 19 Dec, 2024 Reviewers invited by journal 19 Dec, 2024 Editor assigned by journal 14 Nov, 2024 First submitted to journal 12 Nov, 2024 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5444183","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":392322671,"identity":"98ef4cde-0fc4-440c-917e-6b05a9b6d537","order_by":0,"name":"Anand Kumar Mandal","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Anand","middleName":"Kumar","lastName":"Mandal","suffix":""},{"id":392322672,"identity":"045185b4-548c-49be-9b3f-9715da53b1ab","order_by":1,"name":"Rakesh Kumar","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Rakesh","middleName":"","lastName":"Kumar","suffix":""},{"id":392322673,"identity":"393d724d-940a-4245-a33a-bfcfe9c51e28","order_by":2,"name":"Bikash Kumar","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAwUlEQVRIiWNgGAWjYBACCRDB2GDDwMbAkABi8xCrJY2BjY1ELYcZQNYQByRnZCd+rtxxPo9PvuEBw48aBhlzQlqkJXI3S549c7sY5DDGnmMMPJYNBLTISeRukGxsu53YBvILbwMDj8EBwlo2/2xsOwfWwviXGC1Ah20D2nIArIWZKFske95us2w8kwzUkpBwWOaYBGEtEsdzN99s3GGXOL/5TOLDNzU29gS1IAGehAPQeCIasJNg/CgYBaNgFIwoAAD+zTydf3p1yAAAAABJRU5ErkJggg==","orcid":"","institution":"NITJ: Dr BR Ambedkar National Institute of Technology","correspondingAuthor":true,"prefix":"","firstName":"Bikash","middleName":"","lastName":"Kumar","suffix":""},{"id":392322674,"identity":"65de5842-04b0-4c1d-ab2a-5efdab173dc1","order_by":3,"name":"Deepika Rani","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Deepika","middleName":"","lastName":"Rani","suffix":""}],"badges":[],"createdAt":"2024-11-13 06:21:19","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-5444183/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-5444183/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-16218-y","type":"published","date":"2025-08-01T16:06:01+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":88268336,"identity":"8f434543-48c0-4cd6-8df7-c129617514be","added_by":"auto","created_at":"2025-08-04 16:51:07","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":2277562,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript1.pdf","url":"https://assets-eu.researchsquare.com/files/rs-5444183/v1_covered_7ecfb748-9743-48bc-8f53-250c5db46d47.pdf"}],"financialInterests":"","formattedTitle":"Probing the Effect of Pre- and Post-heating in Resistance Spot Welded Multi-material TWB system through Response Surface Methodology","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Resistance spot welding, Tailor Welded Blank (TWB), Response Surface Methodology (RSM), Analysis of Variance (ANOVA), Electron Back-Scatter Diffraction (EBSD) analysis, Desirability function","lastPublishedDoi":"10.21203/rs.3.rs-5444183/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-5444183/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study investigates the optimization of the resistance spot welding (RSW) process in a three-sheet, multi-material configuration, utilizing steel alloys of varying thicknesses, namely, AISI 1035 (1.2 mm), ASTM A36 (2.0 mm), and IFHS 350 (2.5 mm). 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