The objectives of this research are: (1) optimum design and control of the resistance brazing process using Taguchi-class optimization techniques; (2) investigation of the influence of process parameters on mechanical and electrical properties of the brazed joints; and (3) development of a physical model based on microstructural analysis in order to rationalize the results and to enhance the understanding of brazeability of electrical contacts made out of dispersion-strengthened composites. This study includes the development of an experimentally- based process model using Taguchi's experimental design approach. The signal-to-noise ratio method will be used to analyze the results in order to explore the optimum process conditions that yield the best joint quality with minimum variation about the target value. The results of the metallurgical investigation will be correlated with fracture loads, fracture surface, and resistivity of the brazed joint. This will provide a better understanding of the dependence of brazing joint microstructure on processing variables such as brazing current, heating time, electrode force, and joint clearance.
