A study of weld quality in ultrasonic spot welding of similar and dissimilar metals

Al-Sarraf, Z. and Lucas, M. (2012) A study of weld quality in ultrasonic spot welding of similar and dissimilar metals. Journal of Physics: Conference Series, 382(C1), Art. 012013. (doi: 10.1088/1742-6596/382/1/012013)

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Abstract

Several difficulties are faced in joining thinner sheets of similar and dissimilar materials from fusion welding processes such as resistance welding and laser welding. Ultrasonic metal welding overcomes many of these difficulties by using high frequency vibration and applied pressure to create a solid-state weld. Ultrasonic metal welding is an effective technique in joining small components, such as in wire bonding, but is also capable of joining thicker sheet, depending on the control of welding conditions. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal welding device. The ultrasonic welding horn is modelled using finite element analysis and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. Control of the vibration amplitude profile through the weld cycle is used to enhance weld strength and quality, providing an opportunity to reduce part marking. Optical microscopic examination and scanning electron microscopy (SEM) were employed to investigate the weld quality. The results show how the weld quality is particularly sensitive to the combination of clamping force and vibration amplitude of the welding tip.

Item Type:Articles
Status:Published
Refereed:Yes
Glasgow Author(s) Enlighten ID:Lucas, Professor Margaret
Authors: Al-Sarraf, Z., and Lucas, M.
College/School:College of Science and Engineering > School of Engineering > Systems Power and Energy
Journal Name:Journal of Physics: Conference Series
Publisher:Institute of Physics
ISSN:1742-6588
ISSN (Online):1742-6596
Published Online:22 August 2012

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