Ultrasonic joining of lightweight alloy/fiber-reinforced polymer hybrid structures

This chapter presents the basics of the Taguchi design of experiments (DoE) and response surface methodology (RSM), with focus on their application for a profound understanding and optimization of metal-polymer joining technologies. It also presents case studies for Taguchi design and Response Surface Method that are examples from research works within the Advanced Polymer-Metal Hybrid Structures Group at the Helmholtz-Zentrum Geesthacht, Germany, and its international cooperation projects. The most common RSM DoEs are the three-level full factorial, the Box-Behnken, and the Central Composite. The selection of the Taguchi DoE in substitution to a full-factorial DoE has shown to be an interesting tool to an initial understanding of microstructure and mechanical performance of friction spot double-lap joints. The DoE approach designed by Taguchi is a powerful statistical method that enables optimizing the performance of a product, process, design, and system with a significant reduction in experiments, time, and costs.