Review of advanced resistance welding technologies and control methods for joining state-of-the-art materials in lightweight and electric vehicle manufacturing

Podržaj, Primož (author), Klobčar, Damjan (author)

Resistance spot welding (RSW) remains a fundamental joining process in modern industrial manufacturing, particularly in the automotive sector. Ensuring consistent weld quality is critical, prompting the development and integration of various monitoring and control systems. This paper reviews the theoretical foundations of RSW and explores diverse control strategies from a control systems perspective. A comprehensive overview of contemporary quality assurance methods—including those leveraging artificial intelligence and machine vision—is provided. The paper also examines the evolving role of RSW in lightweight automotive design and the production of electric vehicles, where diverse materials and dissimilar metal combinations are increasingly common. To address the challenges of welding these advanced materials, state-of-the-art welding and joining technologies are discussed in detail.

• Language: English
• Keywords: artificial intelligence, control systems, machine vision, resistance spot welding, advanced joining technologies
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2025
• Number of pages: Str. 23-32
• Numbering: Vol. 50, no. 1
• PID: 20.500.12556/RUL-180344
• UDC: 621.791.763:004.85
• ISSN on article: 2620-0325
• DOI: 10.24867/ATM-2025-1-004
• COBISS.SI-ID: 270725891
• Publication date in RUL: 06.03.2026

Record is a part of a journal

• Title: Advanced technologies and materials
• Publisher: Univerza Novi Sad, Fakultet tehničkih nauka
• ISSN: 2620-0325
• COBISS.SI-ID: 323825159

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Keywords: umetna inteligenca, sistemi krmiljenja, strojno učenje, uporovno točkovno varjenje, napredne tehnologije spajanja materialov