Abstract
Resistance welding is to bond two pieces of metal materials together by melting the materials in the contact area. An elevated temperature is generated by contact resistance when electrical current flows through the contact area of the two materials. Generally, a current is applied through two close electrodes. Sometimes, however, it is necessary to set the two electrodes far apart when the contact area is physically unreachable. The far separation of the electrodes makes difficult to generate reliable welds. This paper describes a reliability and robustness design method for the welding process. In particular, a concept design was conducted to avoid welding failure modes. The critical dimensions of a work piece were defined to make a successful weld. Then the welding processes for various dimensions of the work pieces were optimized using Taguchi's parameter design method. A thermal cycle test was performed to evaluate the reliability of the welds. It is shown that the welding process is robust and the welds have high reliability.
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