Abstract
A finite element model of ultrasonic consolidation (UC) is developed to investigate the slip to stick transition time during the UC bonding process. A methodology is established to determine the transition from sliding friction from the initiation of the UC bonding process to the onset of bonding using an energy criterion and geometry changes during bonding of foils with UC. Sliding friction is shown to occur for a large fraction of the weld time; however, the majority of deformation and heat generation occur during the volumetric deformation (stick) phase. The model results are compared with experiments over a range of weld times, and good agreement is found with experimental measurements of UC.
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