Advanced analysis of the properties of solid-wire electric contacts produced by ultrasonic welding and soldering

Logar, Andraž (author), Klobčar, Damjan (author), Nagode, Aleš (author), Trdan, Uroš (author), Černivec, Gregor (author), Sharma, Abhay (author)

The current article presents an advanced analysis of the properties of solid-wire electric contacts produced with ultrasonic welding and soldering. Soldering is generally used to join thin, solid copper wires to produce electrical contacts in small-volume production, as ultrasonic welding does not provide acceptable peel force and tensile strength due to the deformation and thinning of the wires. In this article, ultrasonic welding of thin, solid copper wires using a ring before and after a thermal shock test is discussed and compared with the standard soldering technique. The thermal shock test was carried out in the temperature range from −30 to 150 °C. Half of the samples, for both the joining techniques and the wires, were subjected to the thermal shock test; the other half were not. Investigations included electrical resistance tests, optical and SEM microscopy, XRD, microhardness measurements, peel tests, tensile tests, and fractographic analysis. The electrical resistance test, microscopy, microhardness measurements, and fracture examinations showed no differences between the thermal shock-exposed and the non-exposed samples with the same joining process. In mechanical tests, the ultrasonic joint demonstrated superior strength compared to the soldered joint.

• Language: English
• Keywords: solid copper wires, ultrasonic welding, soldering, thermal shock test, joint strength, electrical conductivity
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2024
• Number of pages: 15 str.
• Numbering: Vol. 17, iss. 2, [article no.] 334
• PID: 20.500.12556/RUL-153501
• UDC: 621.791
• ISSN on article: 1996-1944
• DOI: 10.3390/ma17020334
• COBISS.SI-ID: 180397827
• Publication date in RUL: 10.01.2024

LOGAR, Andraž, KLOBČAR, Damjan, NAGODE, Aleš, TRDAN, Uroš, ČERNIVEC, Gregor and SHARMA, Abhay, 2024, Advanced analysis of the properties of solid-wire electric contacts produced by ultrasonic welding and soldering. Materials [online]. 2024. Vol. 17, no. 2,  334. [Accessed 26 April 2025]. DOI 10.3390/ma17020334. Retrieved from: https://repozitorij.uni-lj.si/IzpisGradiva.php?lang=eng&id=153501

Record is a part of a journal

• Title: Materials
• Shortened title: Materials
• Publisher: MDPI
• ISSN: 1996-1944
• COBISS.SI-ID: 33588485

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Keywords: bakrene žice, ultrazvočno varjenje, spajkanje, test termičnega šoka, trdnost spoja, električna prevodnost