Methods for determining a melt layer thickness associated with a predetermined weld strength based on a correlation therebetween

A method for producing welds having a predetermined weld strength, the method comprising:

• forming a first plurality of sample assemblies using a first value of a first weld process setting;
• forming a second plurality of sample assemblies using a second value of the first weld process setting value, the second value being different than the first value;
• measuring a first melt layer thickness of a weld joint of at least one the first plurality of sample assemblies and a second melt layer thickness of a weld joint of at least one of the second plurality of sample assemblies;
• measuring a first failure load of at least one the first plurality of sample assemblies and a second failure load of at least one of the second plurality of sample assemblies;
• and
• responsive to determining that the first failure load corresponds to a predetermined weld strength, forming a production assembly including a weld joint having a melt layer thickness that is substantially the same as the first melt layer thickness,
• wherein the first weld process setting is a weld velocity or a dynamic hold velocity.