Resistance Microwelding of SUS304 Stainless Steel Fine Wire

Abstract

Resistance microwelding of fine crossed stainless steel wires is of increasing industrial importance for medical devices. Therefore, a study has been performed to clarify the basic joining mechanisms. The effect of main process parameters such as welding current, force and weld time were investigated by detailed mechanical testing and metallurgical examinations. Especially, joint strength and microstructures were sensitive for welding current and force. It should be noted that no fusion nugget was formed at the weld interface. Since the joint breaking force was determined by bond area and interfacial strength in the case of interfacial fracture, both of them are needed to be optimized to obtain sound joint. Moreover, heat affected zone should be minimized. A bonding mechanism with several main process stages, wire collapse, surface melting, liquid phase squeeze out and solid-state bonding, was proposed.

Bonding Mechanisms in Resistance Microwelding of 316 Low-Carbon Vacuum Melted Stainless Steel Wires

“…In the case of Auplated Ni wire, the optimized bonding mechanism of RMW was a combination of solid-state bonding, brazing, and fusion welding. [8] Recently, Fukumoto et al [1] investigated RMW of SUS304 SS wire, which is an austenitic SS. Solid-state bonding was again suggested over fusion welding at the optimum JBF.…”

“…[1] In particular, 316 low-carbon vacuum melted (LVM) wire has been used in medical instruments for several decades. Various welding processes [2,3] have been used to fabricate these components; however, limited literature exists on microwelding of austenitic SS used in medical devices.…”

“…Various welding processes [2,3] have been used to fabricate these components; however, limited literature exists on microwelding of austenitic SS used in medical devices. [1,4] Resistance welding has been widely used in the electrical and medical industries, because it is an economical process that offers improved productivity and equipment costs compared to laser welding. Medical devices are miniature and integrated, which results in a reduction of scale in joint size from millimeters (mm) to micrometers (lm) in such applications including, but not limited to, biosensors, stents, catheters, pacemakers, and surgical instruments.…”

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

“…This is confirmed by many researchers in their literature. [7][8][9] Nevertheless, more endeavors should be contributed to the study of RMW of insulated Cu wire to dissimilar metals because of their extensive applications in electrical and electronic industries.…”

“…[1][2][3][4][5][6] Researches on the RMW of a variety of materials including crossed nickel wire, 7) stainless steel wire, 8) Pt wire to stainless steel 9) and nickel-free austenitic stainless steel 10) etc. had been performed.…”