Effect of Temperature Distribution in Ultrasonically Welded Joints of Copper Wire and Sheet Used for Electrical Contacts
Abstract
:1. Introduction
2. Experimental Details
3. Finite Element Analysis
3.1. CAD Model
3.2. Material Properties
3.3. Element Selection and Meshing of CAD Model
3.4. Assumptions for Thermal Analysis
- Unsteady state is considered for thermal analysis.
- Full contact is established with no air gap between the specimens.
- Room temperature is 30 °C.
- The area in which the friction is effective is assumed to be the area of deformation
- Surfaces exposed to air are set under free convection.
3.5. Measurement of Area of Deformation
3.6. Calculation of Heat Flux
4. Simulation and Experimental Trials
5. Results and Discussions
6. Conclusions
- The results from simulation and experiments conducted based on Taguchi’s L9 orthogonal array reveal that the maximum temperature developed during welding is less than the melting point of the work material, validating that the USMW is a solid state welding process.
- It is observed from the analysis that the influence of heat generated due to deformation and friction is significant in the process of formation of joint. The results of temperature from simulation are found to be in good agreement with results of temperature from experiments measured using thermocouple. Thus, the developed finite element model is validated.
- The results of temperature developed at the interface are compared with results of strength of the joint under tensile loading. It is inferred that the strength of the joint correlate well with the temperature developed at the interface indicating that the temperature at the interface has significant effect on strength of the joint. It is observed that the strength of the joint depends on the variations of heat generated during welding under different process parametric conditions.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Factors | Units | Designation | Level 1 | Level 2 | Level 3 |
---|---|---|---|---|---|
Clamping force | N | A | 795 | 995 | 1195 |
Amplitude of vibration of sonotrode | µm | B | 30 | 42.5 | 57 |
Weld time | second | C | 2 | 2.5 | 3 |
Properties | Value |
---|---|
Young’s Modulus (GPa) | 115 |
Poisson ratio | 0.3 |
Density (kg/m3) | 8940 |
Thermal conductivity (W/m °C) | 391 |
Specific heat (J/Kg °C) | 385 |
Thermal expansion co-efficient(°C−1) | 1.66 × 10−5 |
Trial No. | Clamping Force (N) | Amplitude of Vibration of Sonotrode (μm) | Weld Time (s) | Temperature from Simulation (°C) | Temperature from Experiments (°C) | Strength of the Joint in Tension * (N) | ||
---|---|---|---|---|---|---|---|---|
Trial 1 | Trial 2 | Average | ||||||
1 | 795 | 30 | 2 | 79.26 | 79.97 | 79.73 | 79.85 | 187.721 |
2 | 995 | 30 | 2.5 | 110.9 | 110.06 | 110.25 | 110.16 | 210.107 |
3 | 1195 | 30 | 3 | 137.2 | 137.38 | 137.01 | 137.20 | 224.946 |
4 | 795 | 42.5 | 2 | 83.27 | 83.25 | 83.39 | 83.32 | 193.548 |
5 | 995 | 42.5 | 2.5 | 117.8 | 117.55 | 117.73 | 117.64 | 213.342 |
6 | 1195 | 42.5 | 3 | 139.9 | 139.01 | 139.38 | 139.20 | 227.621 |
7 | 795 | 57 | 2 | 99.16 | 99.74 | 99.37 | 99.56 | 202.369 |
8 | 995 | 57 | 2.5 | 119.5 | 119.60 | 119.00 | 119.30 | 217.638 |
9 | 1195 | 57 | 3 | 141.2 | 141.13 | 141.87 | 141.50 | 231.432 |
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Pradeep Kumar, J. Effect of Temperature Distribution in Ultrasonically Welded Joints of Copper Wire and Sheet Used for Electrical Contacts. Materials 2018, 11, 1010. https://doi.org/10.3390/ma11061010
Pradeep Kumar J. Effect of Temperature Distribution in Ultrasonically Welded Joints of Copper Wire and Sheet Used for Electrical Contacts. Materials. 2018; 11(6):1010. https://doi.org/10.3390/ma11061010
Chicago/Turabian StylePradeep Kumar, Jeyaraj. 2018. "Effect of Temperature Distribution in Ultrasonically Welded Joints of Copper Wire and Sheet Used for Electrical Contacts" Materials 11, no. 6: 1010. https://doi.org/10.3390/ma11061010