This study involves implementing an intelligent controller using the fuzzy control algorithm to minimize cold weld and splash in inverter AC spot welding. This study presents an experimental curve of a welding output current and the maximum value of the Instantaneous Heating Rate (IHRmax) using the contact diameter of an electrode as the parameter. It also presents the experimental curve of a welding output current and the slope (S) of the instantaneous dynamic resistance using the instantaneous contact area of an electrode as the parameter. To minimize cold weld and splash, this study proposes an intelligent controller that controls the optimum welding current in real time by estimating the contact diameter of an electrode and the contact area of the initial welding part.