Welding characteristics of coated twisted wire and copper plate by ultrasonic vibration source using a transmission rod with helical slits

Abstract

Conventional ultrasonic welding uses one-dimensional linear locus vibrations. However, this method is problematic in that it produces low weld strengths due to low vibration energy. We focus on generating a two-dimensional planar locus by simultaneously driving two orthogonal vibrations. This paper describes our investigation of an ultrasonic vibration source with a welding tip having helical slits capable of producing two-dimensional planar vibration. Using three types of vibration, including the planar vibration produced by this ultrasonic vibration source, we performed welding experiments under varying conditions for static pressure, welding time, and vibration amplitude, and further observed stripping of coating from a coated twisted wire. The results show the superiority of planar vibration over other types of vibration in terms of weld strength and stripping of coating.