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Meeting 2019 TMS Annual Meeting & Exhibition
Symposium TMS-DGM Symposium on Lightweight Metals: A Joint US-European Symposium on Challenges in Light Weighting the Transportation Industry
Presentation Title Mechanical and Microstructural Characterization of Ultrasonic Metal Welded Large Cross Section Aluminum Wire/Copper Terminal Joints
Author(s) Andreas Gester, Guntram Wagner, Ingo Kesel, Friedhelm Guenter
On-Site Speaker (Planned) Andreas Gester
Abstract Scope In cable harness production the substitution of copper with aluminum wires is pursued more and more as the weight of aluminum is 50 % lower than that of copper considering to reach the same conductivity and an additional cost decrease of 2.5 times. Moreover joining Al-wires to copper terminals is often realized via crimping, which shows several disadvantages especially for cross sections of more than 10 mm˛, e.g. reduced conductivity due to the oxide layers on aluminum or electrochemical corrosion of the contact points. Ultrasonic metal welding is a promising technology, which can avoid these problems. With the availability of torsional ultrasonic welding machines joining of aluminum wires with cross sections of up to 200 mm˛ is possible. Recent investigations focus on the microstructural and mechanical properties of large cross section aluminum wire to copper terminal joints.
Proceedings Inclusion? Planned: Light Metals


A Novel Flexible SSM and HPDC Equipment to Process Secondary Aluminium Alloys for Decarbonising Lightweight Parts in Automotive Sector
A Theory for Designing Ductile Materials with Anisotropy
Assessing the Impact of Texture and its Gradients on the Forming Limits of an AA6xxx Sheet Alloy
D-35: Development of New Magnesium Alloy Strengthened by Nano Second Phase Precipitation
D-36: Issues of Castability of Magnesium Alloys
Effect of Split Sleeve Cold Expansion on the Residual Stress, Texture and Fatigue Life of Rolled AZ31B Magnesium Alloy
Increasing the Strength and Electrical Conductivity of AA6101 Aluminum by Nanostructuring
Influences of SiC Particle Additions on the Grain Refinement of Mg-Zn Alloys
Mechanical and Microstructural Characterization of Ultrasonic Metal Welded Large Cross Section Aluminum Wire/Copper Terminal Joints
The Dependence of Local Strain Distribution on Quench Rate for Extruded Al-Mg-Si-Mn-Fe Alloys
The Effect of through Thickness Texture Variation on the Anisotropic Mechanical Response of an Extruded Al-Mn-Fe-Si Alloy
The Effects of Strontium Addition on the Microstructures and Mechanical Properties of Al-7Si Alloy Reinforced with In-situ Al3Ti Particulates

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