Optimization of resistance welding process of copper power pins

This study is describing the optimization of a resistance welding process, where CuSn0.15 power pins are welded together over an assembled PCB. The aim of the optimization was to reduce the amount of metallic particles generated during the welding process, while maximizing the mechanical strength of the joint and to minimize the risk of creating cracks in the pins. The main influencing factors were determined by Ishikawa analysis, the improvements realized during the optimization include electrode geometry and welding frequency change. The optimized parameters were found by DoE methodology. The optimal process parameters are introduced and tested in industrial environment.