We currently need to buy an ultrasonic metal welder for electric vehicle battery tab welding. The materials we need to weld are 2 layer of 0.2mm Al to 1.7mm Al extrusion, and 2 layer of 0.2mm Ni coated Cu to 1.7mm Al extrusion. We got some problem on the maximum power required for the welder.
use vibration energy instead of current in teh standard heat input formulae
The oscillation frquency and the amplitude of the vibration are important parameters by the ultrasonic generator. Check the generator ouput watts for the metal welding.
Thanks for all the answers.
Here I just want to summarize all the information that I got. I hope it will be helpful for people who is doing similar research as me.
The power required for ultrasonic welding: P=F*V, where F is clamping force, V is sonotrode vibration velocity. Since the ultrasonic vibration is a sinusoidal motion, V=Pi*f*D, where Pi is 3.1415926, f is frequency and D is peak to peak amplitude. F is determined by the clamping pressure (Pc) and welding area (A). So P=Pc*A*Pi*f*D, and power required for a ultrasonic welding will be determined by clamping pressure, welding area, ultrasonic frequency and vibration amplitude.
For Ni coated Cu, because it is harder and stronger than Al, a higher clamp pressure and vibration amplitude will be required, so a much higher power will be required.
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