Industrial Equipment & Machinery
Industrial Equipment Manufacturer
Gregory Ferguson, Lead Engineer
How designed experiments solved a difficult ceramic-to-metal bonding problem that seemed too complicated.
The Challenge
Ceramic component coated with metallic layer not bonding properly. Initially unclear which factors were critical.
The Solution
Series of designed experiments over several months. Varied paste coating, time, and temperature. Brazed Kovar metal strip and measured removal force. Covered every possible factor in bonding process.
The Results
Determined strong correlation between type of grinding wheel used to prepare ceramic surface and final bond strength. Identified specific grinding wheel type producing strongest ceramic:metal bond.
"This was one of the more difficult problems I've worked on. I almost thought it was too complicated to solve. But by using designed experiments, I was able to sort through the data and understand the process."
— Gregory Ferguson, Lead Engineer
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