Optimizing the Joining Strength of Wire Splices using Ultrasonic Metal Welding

Gohari, Mehri; Abedini, Rezvan

doi:10.48311/mme.2025.27866

Optimizing the Joining Strength of Wire Splices using Ultrasonic Metal Welding

Document Type : Original Research

Authors

Mehri Gohari ¹

Rezvan Abedini ²

¹ Iran university of science and engineering

² Iran University of Science and Engineering

10.48311/mme.2025.27866

Abstract

Wire splicing using ultrasonic metal welding technology is one of the important solutions in the production of quality and modern vehicles. The important challenge in this technology is to properly adjust the important process parameters with the aim of achieving higher joint strength and desirable metallurgical properties. For this purpose, in the present study, using the Response Surface Method (RSM), the effect of two parameters, static pressure and welding energy, on the strength of the Cu wire/wire joint with a total cross-sectional area of 10 mm² has been investigated. Metallurgical examination of the welding, including optical imaging and hardness measurement at the joint section, has also been performed and used in the analysis of the results of Design of Experiment (DOE). Based on the DOE results, both static pressure and welding energy parameters were found to be effective, although the effect of welding energy is much greater than pressure. The optimal value of welding energy was found to be 930J and the maximum joint strength was found to be 782N. The minimum and maximum hardness values were 61 and 80 HV, respectively, which indicates strain hardening in the areas in contact with the horn and anvil, while thermal softening in the central areas of the wire splice

Keywords

Ultrasonic Wire Splicing

Joining

Copper Wire

Design of Experiment (DOE)

Weld Strength

Subjects

Welding

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