Application of statistical methods and optimization techniques in terminating ignition coil primary magnet wire without prior removal of insulation

Concerns with stripping and soldering primary copper magnet wire in ignition coils and other related products have led to the investigation of an alternative product and process design, microjoining. Response surface methodologies, mathematical modeling and optimization of the process using nonlinear design of experiments have been used to provide a breakthrough welding process that is an alternative to soldering. The statistical methods used to develop the process build on the current documented research efforts. These results significantly extend the level of knowledge of designed experiment application in the welding field. A new level of insight into microjoining is developed from the results obtained with the response variable assessment methods developed, predictor interaction effects outlined and optimized nonlinear model developed.