The Effects of the Main Variables in the percussive Arc Welding of Electrical Interconnections

Before accepting percussive arc welding as a production process for making electrical interconnections, it was necessary to determine the effects of the main variables (materials, equipment, and operators) which are certain to be encountered in production. This report deals with a study made to develop the required information. The variables selected for study were materials (wire lots and connector pin lots), operators, and welding machines, each variable at two levels. Two different wire types were investigated. Statistically designed experiments were performed to determine the effects of these variables upon flexing strength, tensile strength, and electrical resistance. In general, significant effects were found for wire lots, operators, and welding machines (usually as interactions.) Although these effects are significant, the magnitude of the change does not appear to be excessive in terms of mean values. These results show that the process is controllable and that initial process standards can be calculated from the data presented.