Experimental investigation on ultrasonic metal welding of copper sheet with copper wire using Taguchi method

Ultrasonic metal welding (USMW) is a prominent solid state technology implied for bonding non-ferrous metals without utilizing filler materials. In USMW, the imperious mechanism is the solid state bonding which is achieved by plastic deformation and slip. Copper sheets bonded with Cu wires plays vital role in various applications like alternator, electrical and electronics industries, etc. This experimental work is being done to perceive the mechanism of the USMW process and also to find the optimal welding parameters like workpiece holding pressure, welding amplitude and welding duration for copper sheet to copper wire by Design of Experiment (DOE) adopting Taguchi methodological means to improvise the weldment strength. Moreover, L27 orthogonal array (OA) based on Design of Experiment to conduct sequence of experiments has been selected. Experiments were carried for 0.3 mm thick copper sheet with U 1.2 mm Cu wire and the weldment strength for all the run were calculated employing data acquisition system (DAQ) tensile testing machine. The maximum weld strength is obtained for weld pressure - 4 bar, amplitude - 70 mm and weld time - 4 s. Results acquired from experimental work are validated by confirmation tests and the results are found to be in good. (c) 2021 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Materials Research - 2019.