The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper Joints
Copper joints are indispensable in electronics and the electrical power industry due to their predominant usage in battery pack manufacturing for electric vehicle). Traditional joining methods are often limited by oxidation-related challenges. Recent efforts have focused on addressing these limitati...
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| Format: | Article |
| Language: | English |
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MDPI AG
2025-02-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/2/55 |
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| author | Koen Faes Rafael Nunes Sylvia De Meester Wim De Waele Hetal Parmar Vitantonio Esperto Felice Rubino |
| author_facet | Koen Faes Rafael Nunes Sylvia De Meester Wim De Waele Hetal Parmar Vitantonio Esperto Felice Rubino |
| author_sort | Koen Faes |
| collection | DOAJ |
| description | Copper joints are indispensable in electronics and the electrical power industry due to their predominant usage in battery pack manufacturing for electric vehicle). Traditional joining methods are often limited by oxidation-related challenges. Recent efforts have focused on addressing these limitations by employing solid-state techniques like ultrasonic welding (USW) for joining similar metals. USW presents attractive advantages such as a lower processing temperature and shorter weld time. This study investigates the ultrasonic welding of Cu-Cu joints with a thickness of 0.5 mm, focusing on both mechanical and metallurgical properties. The influence of key process parameters, such as the welding time, pressure and vibration amplitude, was examined in relation to the welding energy and lap shear strength. Additionally, the relationship between the input energy and lap shear strength was explored. A Pareto chart analysis revealed the standardized effects of these parameters on the welding energy and average lap shear strength. The welding time had a significant influence on the welding energy, while the vibration amplitude had the greatest impact on the joint strength. Longer weld times of 2.50 to 4 s yielded a higher lap shear strength, averaging up to 2.30 kN. Notably, a higher lap shear strength was achieved at lower welding energy levels. |
| format | Article |
| id | doaj-art-3e8531caf1a442cb83186e4f855bdd03 |
| institution | DOAJ |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-3e8531caf1a442cb83186e4f855bdd032025-08-20T02:44:50ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-02-01925510.3390/jmmp9020055The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper JointsKoen Faes0Rafael Nunes1Sylvia De Meester2Wim De Waele3Hetal Parmar4Vitantonio Esperto5Felice Rubino6Belgian Welding Institute, 9052 Zwijnaarde, BelgiumBelgian Welding Institute, 9052 Zwijnaarde, BelgiumDepartment of Electromechanical, Systems and Metal Engineering, Ghent University, 9052 Zwijnaarde, BelgiumDepartment of Electromechanical, Systems and Metal Engineering, Ghent University, 9052 Zwijnaarde, BelgiumDepartment of Industrial Engineering, University of Salerno, 80084 Fisciano, ItalyDepartment of Industrial Engineering, University of Salerno, 80084 Fisciano, ItalyDepartment of Industrial Engineering, University of Salerno, 80084 Fisciano, ItalyCopper joints are indispensable in electronics and the electrical power industry due to their predominant usage in battery pack manufacturing for electric vehicle). Traditional joining methods are often limited by oxidation-related challenges. Recent efforts have focused on addressing these limitations by employing solid-state techniques like ultrasonic welding (USW) for joining similar metals. USW presents attractive advantages such as a lower processing temperature and shorter weld time. This study investigates the ultrasonic welding of Cu-Cu joints with a thickness of 0.5 mm, focusing on both mechanical and metallurgical properties. The influence of key process parameters, such as the welding time, pressure and vibration amplitude, was examined in relation to the welding energy and lap shear strength. Additionally, the relationship between the input energy and lap shear strength was explored. A Pareto chart analysis revealed the standardized effects of these parameters on the welding energy and average lap shear strength. The welding time had a significant influence on the welding energy, while the vibration amplitude had the greatest impact on the joint strength. Longer weld times of 2.50 to 4 s yielded a higher lap shear strength, averaging up to 2.30 kN. Notably, a higher lap shear strength was achieved at lower welding energy levels.https://www.mdpi.com/2504-4494/9/2/55ultrasonic weldingCu-Cu USWwelding energylap shear strengthsolid-state welding |
| spellingShingle | Koen Faes Rafael Nunes Sylvia De Meester Wim De Waele Hetal Parmar Vitantonio Esperto Felice Rubino The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper Joints Journal of Manufacturing and Materials Processing ultrasonic welding Cu-Cu USW welding energy lap shear strength solid-state welding |
| title | The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper Joints |
| title_full | The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper Joints |
| title_fullStr | The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper Joints |
| title_full_unstemmed | The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper Joints |
| title_short | The Influence of Welding Parameters on the Performance of Ultrasonic-Welded Copper-to-Copper Joints |
| title_sort | influence of welding parameters on the performance of ultrasonic welded copper to copper joints |
| topic | ultrasonic welding Cu-Cu USW welding energy lap shear strength solid-state welding |
| url | https://www.mdpi.com/2504-4494/9/2/55 |
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