Investigation of Optimum Welding Parameters in Ultrasonic Welding for Aluminium Foils

The use of welding in today’s manufacturing technology is extensive. Welding is the process of joining similar or dissimilar material combinations. Ultrasonic welding (USW) is a solid state welding process used for rapidly joining a wide range of similar and dissimilar combination of metals and plastics in very short cycle time and without melting the materials being joined. This paper deals with the Ultrasonic welding of thin Aluminium foils. The main objective of this paper is to arrive at an optimum parameter window of ultrasonic welding variables for the above said material. The ultrasonic parameters considered are power, pressure, and weld time, which exhibit significant influence on ultrasonic welds. The effect of the selected ultrasonic welding parameters was studied by conducting adequate trials on the Aluminium foils of 0.05mm thickness. After conducting preliminary trials, twenty six trials were carried out. Samples were subjected to tensile load testing using Honsfield Tensometer to study the joint efficiency. The quantitative values from tensile load testing were analyzed. The independent as well as the combined effect of ultrasonic welding parameters on tensile load were arrived at using regression equations. The investigation resulted in identifying the optimum ultrasonic welding parameters for obtaining an acceptable ultrasonic joint, for 0.05mm thick Aluminium foils.