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Article
Affiliation(s)

1. Department of Polymers, University of Minho, Guimarães 4800-058, Portugal
2. Engineering Department, Aptiv, Lisbon 1600-514, Portugal
3. Polytechnic Institute of Setubal, Setubal 2910-761, Portugal
4. Superior Institute of Engineering, Lisbon 1959-007, Portugal

ABSTRACT

The ultrasonic welding process for wires is being largely used on industry mainly on applications that involve the connection between similar or different metals. The biggest benefit of this technology is the possibility to perform the weld without addition materials, like terminals, metal rings or tapes. Manufacturing of wiring harnesses demands a significant amount of joining, such as welding, crimping or soldering, to fulfill the desired layout of the harnesses and capacity requirements, but conventional connection processes, face difficulties in joining multiple cross sections mainly due to the characteristics of the processes and equipment in use. Ultrasonic metal welding process overcomes these issues due to the solid-state characteristics inherent to the process itself that include the excellent electrical properties of the joint. Several researches on ultrasonic metal welding are being done to define the fundamental mechanisms behind this process and it is being seen that they are completely dependent on the cross section to be welded. With this research we are trying to develop methods for process characterization and define acceptable quality parameters in this process. The main topics addressed in this paper are the characterization the weld formation using copper-to-copper wires using optical microscopy and the analysis of insulation material when submitted to different thermal conditions.

KEYWORDS

Ultrasonic metal welding, wiring harnesses, insulated wires, splices, harness assemblies, PVC (Polyvinyl Chloride).

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