Author ORCID Identifier

Date Available


Year of Publication


Degree Name

Master of Science in Manufacturing Systems Engineering (MSMSE)

Document Type

Master's Thesis




Manufacturing Systems Engineering

First Advisor

Dr. Fazleena Badurdeen


The union of a set of materials by way of Resistance Spot Welding is designed so that once fused together, a substantial amount of intentional, external force must be applied to separate the contents. Therefore, Resistance Spot Welding is often the preferred fusion method in high-volume manufacturing processes. The result of Resistance Spot Welding however is the formation of a weld nugget which is not visible to the naked eye. Destructive and/or ultrasonic methods applied off-line must be used to determine the quality of each weld; both inefficient and expensive processes. The following research analyzes the data fed back during resistance spot weld sequences in-line and establishes a correlation between emitted characteristics and the final quality of a spot weld.

The two characteristics researched to segregate weld quality are: the electrical sin wave signature and the acoustic sin wave signature produced during the welding sequence. Both features were discovered to have a direct correlation to the final quality of a weld once cured. By measuring and comparing these characteristics at the source, an opportunity is presented to decrease time and potential defects by confirming the quality of each weld in-process and at the source.

Digital Object Identifier (DOI)