Consulting Services

Consulting Services

WHAT WE DO FOR YOU

microJoining Solutions (mJS) can save you money by improving yields in your present welding processes and preventing welding failures in your product design phase.
 
mJS has developed a special expertise in welding automotive components and sensors, medical devices, and solar cell assemblies.  mJS is very familiar with both automotive and FDA process documentation and validation.

MICROJOINING SOLUTIONS has extensive experience with improving your welding processes without:
Redesigning your parts
Changing your materials

microJoining Solutions has extensive experience improving poor yield welding processes without redesigning parts or changing part materials. We recognize that our clients need to improve their welding processes NOW! Typical client welding problems include:

  • Cold welds with no adhesion
  • Hot welds with excessive burned surfaces, weld splash, pin holes and voids
  • Weak tensile or peel strength
  • Open welds during environmental testing

microJOINING SOLUTIONS designs weldability into your new product by:

Preventing costly design mistakes, MicroJoining Solutions assists our clients by designing “weldability” into their new products. Most welding mistakes are created in the design stage. Key “weldability components include:

  • Selecting the proper base and plating materials
  • Employing part geometry that balances the thermal loading between parts
  • Ensuring access for resistance welding electrodes or laser beam cone

Upon completion of the design phase, microJoining Solutions works with their clients using the Design of Experiment (DoE) process, coupled with years of “hands on” high and low volume production experience to develop and optimize the welding process by:

  • Defining “weld quality”
  • Identifying the controllable input factors
  • Defining the output responses in relation to the desired weld quality
  • Conducting the DoE with production parts and production equipment
  • Optimizing the welding parameters
  • Conducting confirmation runs to establish Cpk or Six-sigma metrics
  • Setting process limits

MicroJOINING SOLUTIONS combines theoretical and hands-on training including:

Fundamentals of Laser Welding
Design of Experiment for Laser Welding
Fundamentals of Resistance Welding
Design of Experiment for Resistance Welding

microJoining Solutions employs a combination of theoretical and “hands-on” training. Our goal is to make our client engineers and technicians “mini experts” in laser or resistance welding.

Our courses include:

  • Fundamentals of Laser Welding
  • Design of Experiment (DoE) Fundamentals for Laser Welding
  • Fundamentals of Resistance Welding
  • Design of Experiment (DoE) Fundamentals for Resistance Welding

Fundamentals of Laser Welding – Course Outline

  • Definition
  • Heat Generation
  • Basic Laws
  • Bond Types
  • Part Characteristics
  • Optical configurations
  • Energy Control
  • Heat Profile Control
  • Heat Balancing
  • Equipment Set Up

Design of Experiment for Laser Welding – Course Outline

  • Definition
  • Process Application
  • Limitations
  • Basic Approach
  • Medical Device Example
  • Model Selection
  • Model Results
  • Optimized Settings
  • Confirmation Run Procedure
  • Confirmation Analysis
  • Process Limits

Fundamentals of Resistance Welding – Course Outline

  • Definition
  • Heat Generation
  • Basic Laws
  • Bond Types
  • Part Characteristics
  • Energy Control
  • Heat Profile Control
  • Force Control
  • Electrodes
  • Heat Balancing
  • Equipment Set Up

Design of Experiment for Resistance Welding – Course Outline

  • Definition
  • Process Application
  • Limitations
  • Basic Approach
  • Medical Device Example
  • Model Selection
  • Model Results
  • Optimized Settings
  • Confirmation Run Procedure
  • Confirmation Analysis
  • Process Limits