Investigation of Hot-Staking Process Parameters and Evolution of Improvement in Joint Strength

The capability of hot-staking in providing mechanical as well as electrical joints along with its versatility and cost effectiveness makes it a process of preference in electrical and electronics appliances. However, the effectiveness of the process depends only on the mechanical contact and there is no welding or fusion between the joining surfaces. This necessitates proper selection and control of process parameters. This study investigates using Taguchi experiments the importance of process parameters for hot-staked joints in armatures of DC motors. Results show that the electrode material, geometry, and its position are significantly important. Based on the findings, a hypothesis is reasoned about process-product relationship to enable evolving in joint strength.