Graduate Thesis Or Dissertation
 

Sources of weld strength variability in capacitor discharge welding

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https://ir.library.oregonstate.edu/concern/graduate_thesis_or_dissertations/00000288j

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  • Capacitor discharge welding (CDW) is a rapid solidification joining process under the influence of one-dimensional thermal gradients. Although CDW is useful for joining small parts and dissimilar metals, CD welded joints have a large variability in weld strength. CDW is not widely accepted because of a lack of automated process control. Studying the sources of variability in the CDW process can guide the automation of CDW. Therefore, the objectives of this study were to investigate sources of variability that affect weld strength and to generate a model to predict the weld strength variability in CDW. The source of variability was investigated by using screening experiments. Four different materials, stainless steel, Nitronic 50 Steel, copper, and low oxygen copper (C101), were selected to represent various levels of thermal conductivity and absorbed gas content. Thermal conductivity, percentage of gas content absorbed, diameter, and welding time were treated as the independent variables while the dependent variables were the standard deviation of CD weld strength as a percentage of base material strength and the mean of CD weld strength as a percentage of base material strength. A screening experiment and a statistical analysis of the data were used to develop a predictive model of the weld strength variability in CDW. Electron photomicrographs of weld fracture surfaces and dynamic current and resistance curves for each welding cycle were used to support conclusions from the statistical analysis. Conclusions of this study are that thermal conductivity and absorbed gas content do have a significant influence on weld strength variability in CDW.
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