This article presents a systematic study on the effect of input process parameters of the weld-bonding process, namely curing temperature, curing time, welding pressure, welding time and welding current, on the characteristics of the weld bonds, such as bond-line thickness, equivalent nugget diameter, corona size and ultimate shear tensile strength using a Box-Behnken design approach. The effect of overlap length and surface roughness on the shear tensile strength of weld bonds was studied by conducting pilot experiments using a single variable approach. Thereafter, effects of input process parameters, such as curing temperature, curing time, welding pressure, welding time and welding current, on various characteristics of weld bonds was studied by conducting the main experiments according to the Box-Behnken design and response surface methodology (RSM). Regression models were developed to study the influence of input process parameters of weld bonding on characteristics of weld bonds, i.e. bond-line thickness, equivalent nugget diameter, corona size and ultimate shear tensile strength. A combination of weld bonding process parameters for maximum shear tensile strength of the weld bond was obtained with the help of analysis. Further, efforts were made to correlate the bond-line thickness, equivalent nugget diameter and corona size with ultimate shear tensile strength of weld bonds. Developed regression models were validated by conducting confirmation experiments.
展开▼
