Mechanism of Resistance Microwelding of Insulated Copper Wire to Phosphor Bronze Sheet

Bing-hua, MO; Guo, Zhongning; Li, Yuanbo; Huang, Zhigang; Wang, Guan

doi:10.2320/matertrans.m2011013

Cited by 15 publications

(7 citation statements)

References 18 publications

(24 reference statements)

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“…Insulated Cu wire (diameter of 0.1mm with 15_µm_thick modified polyurethane coating) and phosphor bronze sheet (18 mm long, 7 mm wide and 0.2 mm thick) were used in this study. The upper electrode and lower electrode was made of RWMA class 14 (Molybdenum) and RWMA class 2 (CuCr1) [2].…”

Section: Methodsmentioning

confidence: 99%

“…Resistance microwelding (RMW) is an importance microjoining technology which is increasingly used in the fabrication of electronic devices, micro electro-mechanical systems (MEMS) and medical devices, such as batteries, relays, sensors, interconnections in printed circuit boards and pacemaker implants [1][2][3][4]. Compared to the extensive work in normal scale resistance welding, however, very limited information is available for RMW, e.g., recommendations for welding parameter selection and specific international standards on process, materials, and equipment are still lacking [1].…”

Section: Introductionmentioning

confidence: 99%

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Orthogonal Experiment of Resistance Microwelding of Insulated Copper Wire and Phosphor Bronze Sheet

2013

AMR

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The selection of welding parameter has an important effect on weld quality. In this paper, an orthogonal experiment method was used to optimize the resistance microwelding (RMW) parameters for the connection of insulated copper wire and phosphor bronze sheet. An orthogonal array with three factors (welding current, weld time and electrode force) and five levels was used. Joint breaking force (JBF) and surface appearance were selected as the evaluation criterion of the weld quality. The results show that welding current was the most influencing parameter on joint strength, while the electrode force had the most significant effect on the surface appearance. The orthogonal method was proved to be an effective method to obtain the optimum conditions for RMW of insulated copper wire.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Orthogonal Experiment of Resistance Microwelding of Insulated Copper Wire and Phosphor Bronze Sheet

2013

AMR

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“…Conventional joining methods are modified to suit the needs of heterogeneous tiny joints. Resistance micro-welding, laser droplet joining, duothermal soldering process, and precision miniaturized droplet deposition technique are some of the newly evolved techniques [3][4][5][6]. These techniques still need standardization due to diverse material characteristics.…”

Section: Introductionmentioning

confidence: 99%

An FEA based study of thermal behaviour of ultrasonically welded phosphor bronze sheets

Sanga

Wattal

Nagesh

2021

JMES

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The ultrasonic joining of phosphor bronze sheets is analyzed using a 3-D finite element model for the study and prediction of the thermal profiles at the weld interface. The heat fluxes are calculated and assigned as boundary conditions during the thermal simulation. The forecast of temperature is done under various welding conditions. The maximum temperature obtained by transient simulation at the weld interface is 366.74℃. The continuous reduction in the temperature is observed towards the extremes of the weld metal. The sonotrode and the anvil achieve a lower temperature in comparison to the weld interface. The effect of clamping force and bonding ratio on the interface temperature is observed as positive. The model is validated with an error of 1.576% between the observed and predicted temperature results and a correlation co-efficient 0.96 is established between the simulated temperature results and the weld strength. Sufficiently strong joints were obtained at the optimum welding conditions with 74% joint efficiency. It is evident that the interface temperature has a strong linear relationship with joint strength and is a major deciding factor for achieving strong joints.

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“…Chen [ 2 ] studied resistance microwelding of 316L stainless steel to Pt wire and investigated the joint breaking force, fracture mode, and interfacial metallurgical phenomena. Mo et al [ 3 ] focused on the mechanism of resistance microwelding of insulated copper wire to phosphor bronze sheet. They investigated the effects of the main process parameters and joint microstructure.…”

Section: Introductionmentioning

confidence: 99%

Laser Indirect Shock Welding of Fine Wire to Metal Sheet

et al. 2017

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Abstract:The purpose of this paper is to present an advanced method for welding fine wire to metal sheet, namely laser indirect shock welding (LISW). This process uses silica gel as driver sheet to accelerate the metal sheet toward the wire to obtain metallurgical bonding. A series of experiments were implemented to validate the welding ability of Al sheet/Cu wire and Al sheet/Ag wire. It was found that the use of a driver sheet can maintain high surface quality of the metal sheet. With the increase of laser pulse energy, the bonding area of the sheet/wire increased and the welding interfaces were nearly flat. Energy dispersive spectroscopy (EDS) results show that the intermetallic phases were absent and a short element diffusion layer which would limit the formation of the intermetallic phases emerging at the welding interface. A tensile shear test was used to measure the mechanical strength of the welding joints. The influence of laser pulse energy on the tensile failure modes was investigated, and two failure modes, including interfacial failure and failure through the wire, were observed. The nanoindentation test results indicate that as the distance to the welding interface decreased, the microhardness increased due to the plastic deformation becoming more violent.

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Mechanism of Resistance Microwelding of Insulated Copper Wire to Phosphor Bronze Sheet

Cited by 15 publications

References 18 publications

Orthogonal Experiment of Resistance Microwelding of Insulated Copper Wire and Phosphor Bronze Sheet

Orthogonal Experiment of Resistance Microwelding of Insulated Copper Wire and Phosphor Bronze Sheet

An FEA based study of thermal behaviour of ultrasonically welded phosphor bronze sheets

Laser Indirect Shock Welding of Fine Wire to Metal Sheet

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