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Effect of process parameter characteristics on joint strength during ultrasonic metal welding of electrical contacts

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Abstract

Modern customer durable products are subjected to severe operating conditions and require a variety of quality electrical contacts for improved performance and service life in diverse applications. Over a few decades, ultrasonic metal welding process has evolved as a suitable manufacturing technique for large-scale rapid manufacturing of such electrical contacts. In this investigation, the welding parameters such as clamping pressure, amplitude of vibration of the sonotrode, weld time and the part dimensions such as diameter of wire and thickness of the sheet are considered for joining electrical contacts comprising of copper wire and sheet. Experiments are conducted according to the response surface method with two replications to obtain the response of T-peel strength of the joint. The effect of process parameters on the strength of joint is vividly investigated, and a process characteristic map is developed for improvement of the process to produce defect-free electrical contacts. The lower level of clamping pressure (2 bar), medium level of amplitude of vibration of the sonotrode (47.5 μm), weld time (2.5 s), diameter of the wire (1.2 mm) and thickness of the sheet (0.2 m) are found to be effective to produce electrical contacts with maximum strength of the joint of more than 220 N. The results from experiments are utilized to develop a mathematical model for prediction of strength of the joint. The results predicted by using the model are in good agreement with results from experiments.

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Acknowledgements

The author is so thankful to Dr. K. Prakasan Principal of PSG College of Technology, Coimbatore for providing the essential guidance and facility to carry out this work.

Funding

This research was funded by University Grants Commission, New Delhi, under Major Research Project Scheme (F.No.42-876/2013(SR)).

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  1. Department of Production Engineering, PSG College of Technology, Coimbatore, Tamilnadu, 641004, India

    J. Pradeep Kumar

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  1. J. Pradeep Kumar
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Correspondence to J. Pradeep Kumar.

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Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

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Kumar, J.P. Effect of process parameter characteristics on joint strength during ultrasonic metal welding of electrical contacts. Weld World 64, 73–82 (2020). https://doi.org/10.1007/s40194-019-00820-2

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  • DOI: https://doi.org/10.1007/s40194-019-00820-2

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