Determination of proper parameters for ultrasonic welding of copper plate with copper wire strands

Ultrasonic welding parameters originally provided by the components supplier caused negative pull/peel tension results. In this paper, we present a method to find the optimal parameters for the ultrasonic welding of copper elements. These elements represent components inside an electrical harness from automotive industry: coper plate and copper wire strands. The design of experiments (DoE) was used as a method within the Six Sigma approach. We succeeded in obtaining welding parameters that ensure successfully passing the pull/peel tension test.