Resistance mash welding for joining of copper conductors for electric motors

Agapiou, John S.; Perry, Thomas A.

doi:10.1016/j.jmapro.2013.06.014

Cited by 12 publications

(6 citation statements)

References 3 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, the authors of the aforementioned papers used only one of the possible options related to electric servo system control, i.e. control in relation to force control algorithm [13,14]. There is another option of the electric servo control system, highly useful during welding, i.e.…”

Section: Areas Of Applicationmentioning

confidence: 99%

Optimization of resistance welding by using electric servo actuator

2017

View full text Add to dashboard Cite

The paper is focused on the control of resistance projection welding process applied in joining of thin-walled metal elements. The motion of electrode is generated by electric servo actuator that controls the force exerted on electrode or alternatively, just travel itself of electrode. The projection welding has been discussed for welding of 1.5 mm thick DX53 steel sheets where one sheet contains an embossed projection. Apart of electric servo actuator, another source of force has been described, i.e. pneumatic actuator (classical one), for the reason of comparison. The solution where the electric servo operates together with appropriate algorithm makes the new solution that is alternative for classical, pneumatic one. Optimized motion of electrode due to new proposed source of electrode force or/and travel, based on relevant algorithm yields improved quality of joints.

show abstract

Section: Areas Of Applicationmentioning

confidence: 99%

Optimization of resistance welding by using electric servo actuator

2017

View full text Add to dashboard Cite

show abstract

“…A limited number of studies describe that the process is performed using a diffusion bonding furnace with hydraulic load equipment in the temperature range of 600-1000 • C [13,14]. Moreover, recently there has been an interest in Cu-Cu bonded structures with advanced mechanical properties that can be used for the construction of bar-wound stators in vehicles [15] or as components in particle accelerators [16,17]. High-temperature bonding technology is compatible with these applications as the existence of thermal deformation phenomena does not consist of a deterrent factor.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Copper Thermocompression Diffusion Bonding under Vacuum: Microstructural and Mechanical Characteristics

Samouhos

Peppas

Angelopoulos

et al. 2019

Metals

View full text Add to dashboard Cite

The optimization of the autogenous diffusion copper bonding via thermocompression at vacuum environment was investigated. The influence of various bonding parameters on the interdiffusion efficiency was studied in detail at the micro (SEM-EBSD) and nano (TEM) scales. Bonding at 1000 °C for 90 min under pressure (10 MPa) presented optimum structural and mechanical results. Under these conditions, interdiffusion phenomena were observed at a significant extent through the swelling transformation of existing fine grains or the formation of equiaxed copper grains with an orientation parallel to the bond interface. Transmission electron microscopy revealed the importance of the grain size of the base material on the bond quality. In the regions with fine-sized copper grains, the formation of small equiaxed recrystallized twins was observed. Their length within the bonding zone was in the order of 200 and 400 nm. On the contrary, in the regions with coarse grains the interdiffusion was poorer. The processing temperature and duration presented a significant effect on the bonding strength (BS). BS exceeded 100 MPa in case of processing conditions of T ≥ 850 °C and t ≥ 60 min, while the maximum BS value achieved (≈180 MPa) was comparable with the respective value of the base material. The microhardness of the optimum bond reached 55 HV—slightly higher in comparison to the hardness of the initial copper material. The results indicated that the proposed thermocompression process is appropriate for the production of Cu-Cu bonded structures that can be potentially used as electrical components under mechanical stress.

show abstract

“…It is used for joining both metal sheets, screw and nut elements. Two types of projections are used in resistance projection welding technology: full and embossed [2]. In this paper, the authors presented the results of welding tests for nuts with full projections.…”

Section: Introductionmentioning

confidence: 99%

Projection Welding of Nuts with Full Projections with Use of Electromechanical Operating Force System

Mikno¹,

Kowieski²,

Pilarczyk³

2019

eBIS

View full text Add to dashboard Cite

The projection welding of nuts performed using the pneumatic force system (PFS) was subjected to numerical and experimental analysis enabling the identification of the window of welding parameters taking into consideration boundary conditions including expulsion, torsional strength and the deformation of the nut thread. The welding process was subjected to optimisation involving the use of a new, i.e. electromechanical force system (EFS). The optimisation-related approach involved the reduction of welding current and the extension of a welding current flow time in comparison with those obtained when using the pneumatic force system. It was assumed that the acceptance criterion would be the breaking torque not lower than that obtained under the most favourable welding conditions performed using the PFS. The research work involved comparative numerical calculations (performed using the SORPAS software) in relation to both, i.e. the PFS and EFS. The technological welding tests were performed using inverter welding machines (1 kHz) provided with various (electrode) force systems. The research work also included metallographic tests and torsional strength tests. As a result of the application of EFS and a special innovative hybrid algorithm for controlling the initial electrode force, a wider and higher weld core was obtained. The depth of "penetration" into the sheet was also greater. As a result, the welded joint has a higher strength (by 30%). Technological welding tests for the new EFS system were carried out for a 25% lower welding current compared to PFS. Despite the lower welding current for EFS, the welding energy is slightly lower but the welding quality for EPS is significantly higher.

show abstract

Resistance mash welding for joining of copper conductors for electric motors

Cited by 12 publications

References 3 publications

Optimization of resistance welding by using electric servo actuator

Optimization of resistance welding by using electric servo actuator

Optimization of Copper Thermocompression Diffusion Bonding under Vacuum: Microstructural and Mechanical Characteristics

Projection Welding of Nuts with Full Projections with Use of Electromechanical Operating Force System

Contact Info

Product

Resources

About