The application of response surface methodologies to microjoining of magnet wire without prior removal of insulation

Abstract

Concerns with stripping and soldering copper magnet wire in ignition coils and other related products have led to the investigation of an alternative product and process design, microjoining. The use of microjoining with a folded over welding tab terminal design along with a parallel gap welding process provides a suitable method for joining a tin plated brass terminal to the 0.65mm magnet wire without prior removal of the polyesterimide over-coated polyamideimide insulation. Design of experiments, response surface methodologies, mathematical modeling and non-linear optimization have provided an optimized welding process using nonlinear design of experiments that has been used to provide a breakthrough welding process that is an alternative to soldering. The statistical methods used to develop the process build current documented research efforts. Goal programming, weighting methods and other non-linear optimization techniques are applied to welding process models. The dissertation research results significantly extend the level of knowledge of designed experiment applications in the welding field.