Improving Laser Welding Penetration Depth Process Capability for Automotive Seat Adjusters

One of the most important aspects in the fabrication of car seats is the quality of its welded joints. In this proposal, a design of experiments (DoE) approach is used to improve the actual process capability (Cpk) of weld penetration depth in automotive seat adjusters using a laser beam welding (LBW) machine TRUMPF TruDiode 3006. Welding speed effects, laser power, and focal position in the Z axis were considered to determine the optimal welding penetration depth conditions, which is a minimum of 1.20 mm in cold rolled steel metal sheets ZE 790 with a thickness of 1.60 mm. The initial process capability evaluation indicated a Cpk value of 0.50, considering the initial process parameters. The proposed design was modeled using the response surface methodology, stepwise reduction technique, F-test, and before and after process capability evaluation for validation purposes. After applying the proposed methodology, a Cpk of 1.81 was obtained, resulting in a significant improvement of the process, reducing defective parts from 6.51% to 0.00%.