Abstract
A cylindrical tool was applied for ultrasonic bonding of multi-layered copper foil and a copper sheet to prevent damage to the foil during bonding. The strength of the joints bonded with the cylindrical tool was comparable to that of the joints bonded with a conventional knurled tool. The effect of the cylindrical surface tool on bondability was investigated thorough relative motion behaviors between the tool surface and the bonding materials, as well as on bond microstructure evolution. The relative motion was visualized with in-situ observation using a high-speed camera and digital image correlation. At shorter bonding times, relative motions occurred at the bonding interfaces of the foil and the copper sheet. Thereafter, the relative motion between the tool and the bonding material became predominant owing to bond formation at the bonding interface, resulting in a macroscopic plastic flow in the bonded region. This relative motion damaged the foil in knurled tool bonding, and the cylindrical tool achieved bonding without any damage.
Highlights
Ultrasonic bonding is used for manufacturing electrical products in the automotive industry, such as lithium-ion batteries and wire harnesses, because of the short bonding time associated with the process [1]
The principle of ultrasonic bonding is that the interfacial friction between the bonding materials and a normal force causes the removal of oxides and metallurgical adhesion
The objective tool. is results reported far on the effect geometry have been obtained from of the present study is to investigate the effect of the tool geometry on the deformation of multi-layered bonding metal sheets thicker than 0.5 mm
Summary
Ultrasonic bonding is used for manufacturing electrical products in the automotive industry, such as lithium-ion batteries and wire harnesses, because of the short bonding time associated with the process [1]. In the ultrasonic bonding process, micro-bonds are initially formed at the bonding interface owing to the relative motion of the bonding material. A few studies have investigated the ultrasonic bonding of lithium-ion battery materials, such as copper sheet and aluminum sheet [9,10] and copper sheet and Ni-plated Cu sheet [11,12,13]. It has been revealed the initial micro-bonds are formed through the broken Ni layer; thereafter, plastic flow expands the bonded
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