A Study On Ultrasonic Metal Welding Of Bigger Diameter Copper Coil And Wire

This study is to focus on using ultrasonic metal welding between bigger diameter cooper coil(diameter 2mm)and wire.This study is to use bigger diameter cooper coil(diameter 2mm)to connect 2.5mm2 wire and 3mm2 wire in ultrasonic metal welding machine by using different viberation energy.And do a lot of validation tests for these samples.In the process of ultrasonic metal welding between bigger cooper coil and wire,we found it occurred wire openings and broken issue and we designed validation tests to evaluate its risk.Test results shown is that the more ultrasonic welding engery it received,the more likely the welding points will produce wire openings or wire broken phenomenon.Based on this study results we considered to optimize ultrasonic metal welding fixture by adjust welding width in ultrasonic metal welding machine.Finally we defined the right welding width to minimize the wire openings and broken phenomenon.Study results shown it is feasible for using ultrasonic metal welding between bigger diameter copper coil and wire.This result of this research is a new trial for using ultrasonic metal welding and it expands the usage of room for ultrasonic metal welding technology.