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When working with thin layers of comparable and/or different metals, resistance welding and conventional welding each have their own set of limits that they must overcome. When the input parameters include a high-frequency vibration, proper weld duration and pressure, ultrasonic metal welding performs at its highest level of efficiency. Ultrasonic welding uses a lot of power, force and energy, and if the right input parameters aren’t chosen, the quality of the weld and its durability suffer. This study takes into account the relationships between the input process parameters of welding pressure, welding time and vibration amplitude and the output responses of power, force and energy in ultrasonic metal welding (UMW). For multilayer AL-8011 foils, the author utilized UMW has experimented with central composite design by design professionals. The response surface approach, often known as RSM, has been used to improve the process parameters to get the best possible welding connections.

Optimization of process parameters of ultrasonic metal welding for multi layers foil of AL8011 material