Ultrasonic Welding of Cu Alloy Connectors and Conductors Used in the Automotive Industry

This paper aims to highlight the advantages of using the ultrasonic welding process to join Cu alloy connector with Cu conductor wire, materials that are widely used in the automotive industry. Ultrasonic welding is a “cold”, ecological joining process, which does not produce noxious substances and is of great interest for subassembly manufacturers operating in today’s circular economy. In order to optimize the functional parameters for the connector and conductor wire in question, we use a sonotrode (active tool) made of tool steel, at the operating frequency of 20kHz, designed and executed in INCD ISIM Timișoara; experiments were undertaken to define the welding technology parameters for the materials subjected to the experimental investigation. The results were interpreted after the execution of NDT and destructive tests, namely: visual analysis, microscopic and macroscopic investigations; hardness tests.