Logar Andraž, Klobčar Damjan, Trdan Uroš, Nagode Aleš, Černivec Gregor, Vuherer Tomaž
Bosch Rexroth d.o.o., 4210 Brnik, Slovenia.
Laboratory for Welding, University of Ljubljana, 1000 Ljubljana, Slovenia.
Materials (Basel). 2024 Oct 15;17(20):5033. doi: 10.3390/ma17205033.
This article contains an advanced analysis of the properties of solid wire electrical contacts produced by ultrasonic welding, both with and without varnish. The main disadvantage of ultrasonic welding of thin wires is the inability to achieve acceptable peel force and tensile strength, which is mainly due to the deformation and thinning of the wires. This study deals with ultrasonic welding using a ring of thin solid copper wires that minimises the deformation and thinning of the wires. The influence of welding parameters such as energy, pressure and amplitude were systematically analysed. Based on these parameters, the optimum welding programme and control method was determined to weld unvarnished and varnished wires. The investigations included electrical resistance tests, optical microscopy, micro-hardness measurements, peel tests and tensile tests, and the measurement of energy consumption. The results showed no significant differences in microstructure and hardness between varnished and unvarnished joints. Ultrasonic joints of varnished wires achieved lower electrical conductivity (by 38%), lower tensile strength (by 3%) and higher peel strength (by 7%), while the welding process was more sustainable in terms of energy (by 6.6%) and time consumption (without preprocessing).
本文对通过超声波焊接生产的、有无漆层的实心焊丝电触点的性能进行了深入分析。细线超声波焊接的主要缺点是无法获得可接受的剥离力和拉伸强度，这主要是由于导线的变形和变细。本研究采用细实心铜丝环进行超声波焊接，以尽量减少导线的变形和变细。系统分析了能量、压力和振幅等焊接参数的影响。基于这些参数，确定了焊接无漆和有漆导线的最佳焊接程序和控制方法。研究包括电阻测试、光学显微镜检查、显微硬度测量、剥离试验和拉伸试验，以及能耗测量。结果表明，有漆和无漆接头的微观结构和硬度没有显著差异。有漆导线的超声波接头电导率较低（低38%）、拉伸强度较低（低3%）、剥离强度较高（高7%），而焊接过程在能量（低6.6%）和时间消耗（无预处理）方面更具可持续性。
