Joint Design for Electronics Cooling Heat Exchangers Project Example

Delphi Thermal Systems Six Sigma project resulted in a robust product that employs existing Delphi aluminum brazing technologies--Delphi Thermal Systems is using Design for Six Sigma (DFSS) to move Six Sigma upstream, from the manufacturing floor into the product design and development process. In this advanced product development project, DFSS tools and the IDDOV (Identify, Define, Develop, Optimize, Verify) roadmap were used to develop product design and manufacturing process guidelines to join dissimilar metals for a new market application in electronics cooling. The project resulted in a robust, cost-effective, high-performance, low-mass product that employs existing Delphi aluminum brazing technologies for heat exchanger production. Included are five graphs/diagrams. About the authors: David M. Chatt, a certified DFSS Black Belt, is an engineering manager for Delphi Thermal Systems. He has 33 years of experience in automotive HVAC systems, electronics cooling and residential