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Meeting 2023 TMS Annual Meeting & Exhibition
Symposium Advanced Joining Technologies for Automotive Lightweight Structures
Presentation Title A Novel Approach for In-process Monitoring of Dissimilar Ultrasonic Welds of Multi-strand Aluminum Wires and Copper Terminals Utilizing the Seebeck Effect
Author(s) Andreas Gester, Toni Sprigode, Guntram Wagner
On-Site Speaker (Planned) Andreas Gester
Abstract Scope Industrial process monitoring during ultrasonic metal welding of automotive wires and terminals often encompasses sample-based destructive tensile testing as well as the surveillance of welding parameters. Monitoring of all joints down to lot size one and the avoidance of false-positives is not possible with these options, leading to large amounts of pseudo-rejects and undetected faulty welds. However, the increasing substitution of copper wires with light-weight aluminum in automotive wire harnesses, resulting in dissimilar joints of aluminum wires and copper terminals, enables monitoring of other physical properties. Current work focusses on a novel approach for utilizing the thermoelectric effect for process monitoring. In this paper the actual measurement setup is presented and a setup for industrial use is proposed. In order to quantify the correlation between thermoelectric properties, joint strength and the welding parameters previously used for process monitoring Pearson correlation coefficients were determined for all values.
Proceedings Inclusion? Planned:
Keywords Joining, Process Technology,

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Novel Approach for In-process Monitoring of Dissimilar Ultrasonic Welds of Multi-strand Aluminum Wires and Copper Terminals Utilizing the Seebeck Effect
Adhesive Bonding of Lightweight Multi-materials with Surface Modifications
Enabling Multimaterial Joining in Lightweight Automotive Structures Using Novel High Velocity Riveting Process
Impact Welding of an Automotive Component with Vaporizing Foil Actuator
Investigation of Metal Mixing in Laser Keyhole Welding of Dissimilar Metals
Joint Strength Optimization of Single-lap Al 5052-H36 Adhesively Bonded for Off-road Vehicle Chassis Components
Microstructure and Mechanical Properties of Electron Beam Welded AA2024 to AA6061 Dissimilar Joints
Numerical Analysis of High-Velocity Riveted (HVR) Joints through Finite Element Modeling Supported by Experimental Data
Recent Advances in the Transformative Non-fusion Weld-brazing Process Used to Join Thin-gauge Alloys Used in the Automotive Industry
Ultrasonically Assisted Resistance Spot Welding of Multiple Thin Al Foil Stacks for Battery Cell Joining

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