Impact of ultrasonic welding parameters on weldability and sustainability of solid copper wires with and without varnish

Logar, Andraž (author), Klobčar, Damjan (author), Trdan, Uroš (author), Nagode, Aleš (author), Černivec, Gregor (author), Vuherer, Tomaž (author)

This article contains an advanced analysis of the properties of solid wire electrical contacts produced by ultrasonic welding, both with and without varnish. The main disadvantage of ultrasonic welding of thin wires is the inability to achieve acceptable peel force and tensile strength, which is mainly due to the deformation and thinning of the wires. This study deals with ultrasonic welding using a ring of thin solid copper wires that minimises the deformation and thinning of the wires. The influence of welding parameters such as energy, pressure and amplitude were systematically analysed. Based on these parameters, the optimum welding programme and control method was determined to weld unvarnished and varnished wires. The investigations included electrical resistance tests, optical microscopy, micro-hardness measurements, peel tests and tensile tests, and the measurement of energy consumption. The results showed no significant differences in microstructure and hardness between varnished and unvarnished joints. Ultrasonic joints of varnished wires achieved lower electrical conductivity (by 38%), lower tensile strength (by 3%) and higher peel strength (by 7%), while the welding process was more sustainable in terms of energy (by 6.6%) and time consumption (without preprocessing).

• Language: English
• Keywords: solid copper wires, ultrasonic welding, varnish, joint strength, electrical conductivity, ustainability
• 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: 17 str.
• Numbering: Vol. 17, iss. 20, art. 5033
• PID: 20.500.12556/RUL-164278
• UDC: 621.791
• ISSN on article: 1996-1944
• DOI: 10.3390/ma17205033
• COBISS.SI-ID: 212105475
• Publication date in RUL: 18.10.2024

Record is a part of a journal

• Title: Materials
• Shortened title: Materials
• Publisher: Molecular Diversity Preservation International
• 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: polne bakrene žice, ultrazvočno varjenje, lak, trdnost spojev, električna prevodnost, trajnost