Acoustic Emission System for Monitoring Mechanical Behavior During Ultrasonic Metal Welding

Ultrasonic Metal Welding (USMW) is a solid-state metal joining process that produces weld joint by utilization of high-frequency vibration energy to the specimen held together under modest pressure. This paper deals with studies on parametric effects of amplitude, weld time on lap shear test and peel-off during Copper to Copper welding. Experiments of ultrasonic metal welding were performed using Taguchi orthogonal array L9. The mechanical performance of the welded joint was measured using tensometer. The K-type thermocouple was used for in situ temperature monitoring. The piezoceramic Acoustic Emission (AE) sensors were used to in situ monitoring of weld joints. Results show that with an increase in amplitude and weld time, the mechanical performance was also improved during the process.