Analysis of the oscillation behavior during ultrasonic welding of EN AW-1070 wire strands and EN CW004A terminals

Abstract For fulfilling the demand of durable yet lightweight electrical connections in transportation industries, ultrasonic metal welding (USMW) sees widespread use these branches. As ultrasound oscillations utilized procedure occur at a range only few micrometers frequencies 20–100 kHz for an overall duration 50–1500 ms, it is not possible to observe compaction behavior with bare eye. This paper focusses on investigating oscillation horn, anvil, and joining partners during by utilizing array synchronized laser vibrometers performing welds incrementing time stages. The data correlated temperature measurements zone as well tensile testing results. Inter alia formation sidebands fundamental frequency 2nd- 3rd-order harmonics has been observed terminal, wire front face when exceeding optimal weld which would lead maximum joint strength. Following assumption other research groups, cause could be change relative motion components. terminal slipping increasing time, assumed that reason low-frequency movement modulated onto frequency, additionally indicating successful bonding stranded terminal. Furthermore, this anvil increased wear knurls.