Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools
In current automotive lithium-ion battery manufacturing, Ultrasonic Metal Welding (USMW) is one of the major joining techniques due to its advantages in welding multiple thin sheets of highly conductive materials. The sonotrode, serving as the welding tool, transmits high-frequency oscillation to th...
| Main Authors: | , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2023-11-01
|
| Series: | Metals |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-4701/13/12/1935 |
| _version_ | 1797380085669429248 |
|---|---|
| author | Junqi Li Michael Rienks Frank Balle |
| author_facet | Junqi Li Michael Rienks Frank Balle |
| author_sort | Junqi Li |
| collection | DOAJ |
| description | In current automotive lithium-ion battery manufacturing, Ultrasonic Metal Welding (USMW) is one of the major joining techniques due to its advantages in welding multiple thin sheets of highly conductive materials. The sonotrode, serving as the welding tool, transmits high-frequency oscillation to the joining parts. Due to the high frequency of thermal-mechanical loading, the knurl pattern on the sonotrode wears with an increasing number of welds, which significantly influences the welding process, resulting in poor joint quality. In this study, a high-frequency test system was developed to investigate the wear mechanisms of the sonotrode. Based on the comparable relative motion to the welding process, the thermal-mechanical loadings on the contact area were analyzed. As the oscillation amplitude of the sonotrode increased, the estimated frictional force between the sonotrode and the copper counter body remained constant, while an increase in the sliding distance was observed in the contact area. Temperature development showed a strong correlation with mechanical loading. A first approach of continuous testing was performed but was limited due to the failure of the copper counter body under ultrasonic stimulation. |
| first_indexed | 2024-03-08T20:33:06Z |
| format | Article |
| id | doaj.art-c27c6f3ba01b49619d117fc9acf7c5db |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-08T20:33:06Z |
| publishDate | 2023-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-c27c6f3ba01b49619d117fc9acf7c5db2023-12-22T14:24:35ZengMDPI AGMetals2075-47012023-11-011312193510.3390/met13121935Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding ToolsJunqi Li0Michael Rienks1Frank Balle2Walter-and-Ingeborg-Herrmann Chair for Power Ultrasonics and Engineering of Functional Materials, Department of Sustainable Systems Engineering (INATECH), Faculty of Engineering, University of Freiburg, 79110 Freiburg, GermanyWalter-and-Ingeborg-Herrmann Chair for Power Ultrasonics and Engineering of Functional Materials, Department of Sustainable Systems Engineering (INATECH), Faculty of Engineering, University of Freiburg, 79110 Freiburg, GermanyWalter-and-Ingeborg-Herrmann Chair for Power Ultrasonics and Engineering of Functional Materials, Department of Sustainable Systems Engineering (INATECH), Faculty of Engineering, University of Freiburg, 79110 Freiburg, GermanyIn current automotive lithium-ion battery manufacturing, Ultrasonic Metal Welding (USMW) is one of the major joining techniques due to its advantages in welding multiple thin sheets of highly conductive materials. The sonotrode, serving as the welding tool, transmits high-frequency oscillation to the joining parts. Due to the high frequency of thermal-mechanical loading, the knurl pattern on the sonotrode wears with an increasing number of welds, which significantly influences the welding process, resulting in poor joint quality. In this study, a high-frequency test system was developed to investigate the wear mechanisms of the sonotrode. Based on the comparable relative motion to the welding process, the thermal-mechanical loadings on the contact area were analyzed. As the oscillation amplitude of the sonotrode increased, the estimated frictional force between the sonotrode and the copper counter body remained constant, while an increase in the sliding distance was observed in the contact area. Temperature development showed a strong correlation with mechanical loading. A first approach of continuous testing was performed but was limited due to the failure of the copper counter body under ultrasonic stimulation.https://www.mdpi.com/2075-4701/13/12/1935ultrasonic metal weldingsonotrodewearresonancethermal-mechanical analysisLaser Doppler Vibrometry |
| spellingShingle | Junqi Li Michael Rienks Frank Balle Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools Metals ultrasonic metal welding sonotrode wear resonance thermal-mechanical analysis Laser Doppler Vibrometry |
| title | Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools |
| title_full | Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools |
| title_fullStr | Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools |
| title_full_unstemmed | Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools |
| title_short | Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools |
| title_sort | development of a high frequency test system to study the wear of ultrasonic welding tools |
| topic | ultrasonic metal welding sonotrode wear resonance thermal-mechanical analysis Laser Doppler Vibrometry |
| url | https://www.mdpi.com/2075-4701/13/12/1935 |
| work_keys_str_mv | AT junqili developmentofahighfrequencytestsystemtostudythewearofultrasonicweldingtools AT michaelrienks developmentofahighfrequencytestsystemtostudythewearofultrasonicweldingtools AT frankballe developmentofahighfrequencytestsystemtostudythewearofultrasonicweldingtools |