Optimization of process parameters of ultrasonic metal welding for multi layers foil of AL8011 material

Abstract

When working with thin layers of comparable and/or different metals, resistance welding and conventional welding each have their own set of limits that they must overcome. When the input parameters include a high-frequency vibration, proper weld duration and pressure, ultrasonic metal welding performs at its highest level of efficiency. Ultrasonic welding uses a lot of power, force and energy, and if the right input parameters aren’t chosen, the quality of the weld and its durability suffer. This study takes into account the relationships between the input process parameters of welding pressure, welding time and vibration amplitude and the output responses of power, force and energy in ultrasonic metal welding (UMW). For multilayer AL-8011 foils, the author utilized UMW has experimented with central composite design by design professionals. The response surface approach, often known as RSM, has been used to improve the process parameters to get the best possible welding connections.

Keywords:

• Ultrasonic metal welding
• process parameters
• response surface methodology

Acknowledgements

A recommendation was provided by Professors Vishvesh Badheka and Prof.D.M. Patel, both of whom work in the Mechanical Departments of their respective institutions, PDEU and GEC-Palanpur. In addition, the assistance and set-up of experiments provided by the mechanical engineering group at Pandit Deendayal Energy University in Gandhinagar, Gujarat, is very much valued.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Correction Statement

This article has been republished with minor changes. These changes do not impact the academic content of the article.