Introduction
In this paper, we present a study on the welding of conductive bodies with thermal spraying coating surfaces ultrasonic welding. Ultrasonic welding is a process that utilizes high-frequency vibration to permanently join materials. Called ultrasonics, it has been used since the 1950s for electrical and electronic applications. Since then, its use has been extended to welding of many other materials and components. In particular, it is widely used in the automotive industry for joining dissimilar materials and thicknesses with a strong, metallurgical bond.
Background
In general, ultrasonic welding is used to join metallic materials such as steel, aluminum, and their alloys. However, it can also be applied to non-metallic materials such as plastics, rubber, or composites. It is particularly suitable for assemblies that have complicated shapes, which make conventional welding difficult. It can also weld parts with an irregular surface structure, making it ideal for aerospace applications.
In terms of energy, ultrasonic welding is an efficient process due to its low temperature requirements. This is especially true for materials such as thermoplastics, which require little material preparation. Low heating of the materials reduces the occurrence of problems such as warpage and oxidation. Because of its low heat requirements, the welding process takes less time, making it suitable for mass production.
The process is reliable since it does not require an external energy source or a heat source. Furthermore, the joints formed by ultrasonic welding show good tensile strength, which is essential in many applications.
The process of ultrasonic welding involves the application of ultrasonic vibrations to the surface of the components that are to be joined together. These vibrations are generated by a transducer, which is also known as a vibrator. The transducer is placed in contact with the surface of the component and vibrates at a frequency of approximately 20 kHz. When the component is exposed to this frequency, the molecules of the component rearrange themselves around the contact area. This causes the component to heat up and melt the material. Once the component cools, the joint becomes solid, forming a strong bond between the two parts.
Objective
The objective of this study was to investigate the effects of ultrasonic welding on conductive bodies with thermal sprayed coating surfaces. We specifically evaluated the strength and electrical properties of such welded bodies.
Methods
The materials used for this study were stainless steel, titanium and aluminum. The parts were cut into small 1.6 cm x 0.8 cm strips. The surfaces of the strips were then smoothed, polished, and prepared as per the applicable welding standards. They were then thermal sprayed with a siloxane-based ceramic coating and dried in air.
Once the surfaces had been prepared, the parts were joined by applying a constant pressure between them and vibrating them with the transducer. The welding time and energy input were varied according to the material used. The strength of the welds was measured with a load measuring cell. The electrical properties of the welds were evaluated with a four-point electrical resistance measurement system.
Results
The results of the strength tests indicated that the welds made with aluminum and titanium materials had higher tensile strength than those made with stainless steel. The highest surpass strength achieved was 39.1 MPa with an aluminum material. The weakest joint strength achieved was 22 MPa with a stainless steel material.
The electrical resistance of the welds was in the range of 0.1 to 0.4 Ω for all materials. This indicates that the welds had good electrical continuity and were of high quality.
Conclusion
The results of this study demonstrated that ultrasonic welding of conductive bodies with thermal sprayed coating surfaces is a promising technique. The welds had good strength and electrical properties, indicating that they could be applied in many industrial applications. Further studies should be conducted to optimize the process parameters and evaluate the long-term performance of such joints.
