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Resistance spot welding is a method which is commonly used for sheet metal joining purposes in industry due to minimum in thickness it has variation at the time of assembly. Fixturing plays a key role in improving sheet assembly system weld efficiency. As per the survey by American automotive weld quality of the sheet metal assembly process, around 73 percent of the variance problems from pre-production to production were due to fixture based problems. This exertion introduces a new technique of fixture design for the process of sheet metal spot welding. It engrossed on the effect of the fixture location on the dimensional quality of sheet metal parts by considering welding force, clamping force and position of locator. A hybrid optimization technique is used for determining the optimal position and clamping points with finite element analysis and achieved minimum deformation.

In this project work, aluminium oxide/zirconia (30% Al2O3 + 70% ZrO2) and aluminium oxide/chromium (30% Al2O3 + 70%Cr) were coated through atmospheric plasma spray technique (APS) over cast iron as a base material, and some of its mechanical properties were studied experimentally. The hardness, wear and SEM and EDX of Al2O3/ZrO2, Al2O3/Cr coated and non-coated cast iron were taken, and the results were compared. Hardness, SEM and EDX results show that the chromium is better fused with cast iron than zirconium.