Resistance welding is widely used in manufacturing due to its efficiency in joining similar and dissimilar materials. This study investigates the resistance welding of low-density polyethylene (LDPE) and high-density polyethylene (HDPE) composites using stainless steel mesh as a heating element. The effects of welding parameters—current, pressure, and time—on lap shear strength and heat generation are analyzed using Taguchi’s orthogonal array and ANOVA. Multi-response optimization is performed using the technique for order preference by similarity to ideal solution (TOPSIS). Microstructural analysis reveals interfacial and interlaminar failure modes, with higher heat input enhancing weld strength. Results indicate that increasing current and welding time improves both responses, while welding pressure has a varying influence. TOPSIS optimization identifies an optimal parameter combination maximizing lap shear strength and heat generation.
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