Improving laser welding penetration depth process capability for automotive seat adjusters.
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| Title: | Improving laser welding penetration depth process capability for automotive seat adjusters. |
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| Authors: | Tavera-Sainz, Jorge G.1 (AUTHOR) jorgeguillermo.tavera@upaep.edu.mx, Minor-Popocatl, Hertwin1 (AUTHOR), Aguilar-Mejía, Omar2 (AUTHOR), Miranda-Perez, Argelia F.1 (AUTHOR) |
| Source: | Quality Engineering. 2026, Vol. 38 Issue 2, p194-208. 15p. |
| Subjects: | Laser welding, Process capability, Rolled steel, Response surfaces (Statistics), Automobile seats, Experimental design |
| Abstract: | One of the most important aspects in the fabrication of automotive seat adjusters is the quality of their welded joints. In this proposal, the Response Surface Methodology (RSM) Design of Experiments (DoE) approach is applied to improve the current process capability (Cpk) of weld penetration depth in the joint between seat adjuster components—the side panel and upper rail—using a TRUMPF TruDiode 3006 Laser Beam Welding (LBW) machine. The effects of welding speed, laser power, and focal position on the Z-axis were analyzed to determine the optimal conditions for achieving a minimum weld penetration depth specification of 1.20 mm on ZE 790 cold-rolled steel sheets with a thickness of 1.60 mm. The initial process capability assessment revealed a Cpk of 0.50 under the existing process parameter settings. The proposed design was modeled using the stepwise technique, F-test, and process capability assessments (before and after) for validation. After implementing the proposed algorithm, a Cpk value of 1.81 was achieved, resulting in cost avoidance savings of approximately 500,000 USD per year. This improvement reduced the defective parts from 6.51% to 0.00%, representing nearly a three-fold increase in the final Cpk value. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | One of the most important aspects in the fabrication of automotive seat adjusters is the quality of their welded joints. In this proposal, the Response Surface Methodology (RSM) Design of Experiments (DoE) approach is applied to improve the current process capability (Cpk) of weld penetration depth in the joint between seat adjuster components—the side panel and upper rail—using a TRUMPF TruDiode 3006 Laser Beam Welding (LBW) machine. The effects of welding speed, laser power, and focal position on the Z-axis were analyzed to determine the optimal conditions for achieving a minimum weld penetration depth specification of 1.20 mm on ZE 790 cold-rolled steel sheets with a thickness of 1.60 mm. The initial process capability assessment revealed a Cpk of 0.50 under the existing process parameter settings. The proposed design was modeled using the stepwise technique, F-test, and process capability assessments (before and after) for validation. After implementing the proposed algorithm, a Cpk value of 1.81 was achieved, resulting in cost avoidance savings of approximately 500,000 USD per year. This improvement reduced the defective parts from 6.51% to 0.00%, representing nearly a three-fold increase in the final Cpk value. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 08982112 |
| DOI: | 10.1080/08982112.2025.2537086 |
