Optimization of Tensile Strength during Ultrasonic Lap Welding of Dissimilar Metals Using Taguchi’s Philosophy

Abstract

Ultrasonic welding (USW) is a solid-state joining process in which the joint is created between the workpieces by the application of high frequency ultrasonic waves under pressure. Poor weld strength is one of the major problem experienced in the application of such weldments. It is mainly due to improper selection of process parameters. In order to achieve satisfactory weld strength optimization of welding process parameters is indeed essential. In this present context, the USW has been carried out to join dissimilar materials like A1100 aluminum alloy and CuZn37 brass plates of thickness 0.1 mm using Taguchi’s L16 orthogonal array design of experiments. The process parameters like amplitude, weld pressure and weld time have been taken into consideration. Taguchi’s S/N ratio concept has been employed to study the effect of different process parameters on the response like tensile strength; and finally, the optimum setting of process parameters has been decided in view of maximizing tensile strength. The predicted result of the optimized tensile strength has been validated by conducting a confirmatory test. This analysis shows that the high quality and efficient joints can be generated by exploring optimized setting of process parameters which is fruitful in mass production as well as off-line quality control of such a welding practice.