Experimental and Numerical Procedure for Studying Effect of Ultrasonic Spot Weld Parameters on Metal Joints for Electronic Components

  • N. Mohan Raj
  • L. A. Kumaraswamidhas
  • S. Arungalai Vendan
  • K. A. Ramesh Kumar
  • Liang Gao
  • Surinder Singh
  • Harpreet Singh
  • Xiaodong Niu
  • Akhil GargEmail author
Conference paper
Part of the Lecture Notes on Multidisciplinary Industrial Engineering book series (LNMUINEN)


Electrical and automobile industries have high demands for an effective joining of dissimilar materials because of their enormous use. In the present research, numerical and experimental investigations have been conducted to study the effect of parameters of ultrasonic spot weld on metal joints for electronic components. Copper and brass alloy sheets have been welded using ultrasonic spot welding in the lap configuration. Regression analysis in combination with analysis of variance has been applied to formulate the models. Based on the optimum condition determined for the input parameters, mechanical and microstructural analysis is performed using tensile testing and SEM analysis, respectively. Finite-element modelling (FEM) simulation is conducted for the temperature near heat-affected zone (HAZ) and fusion zone (FZ). The results obtained from experiments are compared with the simulation results obtained from FEM modelling. Slight variations in tensile properties of the weldments that are free from defects have been observed with increase in welding time and frequency. A close agreement between the experimental and simulated values of FEM has been observed, which establishes the validity of reasonable accuracy of the model.


Electronic components Ultrasonic metal welding Brass–copper alloy FEM Design of experiments 


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Copyright information

© Springer Nature Singapore Pte Ltd. 2020

Authors and Affiliations

  • N. Mohan Raj
    • 1
    • 2
    • 3
  • L. A. Kumaraswamidhas
    • 3
  • S. Arungalai Vendan
    • 4
  • K. A. Ramesh Kumar
    • 5
  • Liang Gao
    • 6
  • Surinder Singh
    • 7
  • Harpreet Singh
    • 7
  • Xiaodong Niu
    • 1
  • Akhil Garg
    • 1
    Email author
  1. 1.Intelligent Manufacturing Key Laboratory of Ministry of EducationShantou UniversityGuangdongChina
  2. 2.Department of Mechanical EngineeringSri Krishna College of TechnologyCoimbatoreIndia
  3. 3.Department of Mining Machinery EngineeringIndian Institute of Technology (ISM)DhanbadIndia
  4. 4.School of Electrical EngineeringVIT UniversityVelloreIndia
  5. 5.Department of Energy StudiesPeriyar UniversitySalemIndia
  6. 6.State Key Lab of Digital Manufacturing Equipment & Technology, School of Mechanical Science and EngineeringHuazhong University of Science and TechnologyWuhanChina
  7. 7.Department of Mechanical EngineeringIndian Institute of Technology RoparRupnagarIndia

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