This paper is discussing joining technologies for manufacturing of airbag connection cables. For joining cable connectors and cables mostly resistance projection welding will be used: the joint is made between the cable's stranded copper wire and a normally tinned copper terminal plate. So-called compacting of stranded and tinned copper wires, the developed, new resistance projection welding method for joining compacted cables and terminals is demonstrated, followed by a detailed description of the welding technique wire without compacting will be given. Tests were carried out by using tin-coated and uncoated copper wires. Results of mechanical and non destructive tests (peel test, pull-out force test and metallographic cross section analysis) of both types of welded samples, welded by different welding methods have been compared. When resistance projection welding is carried out, sometimes the deviation of welding quality is higher than wished. The main reason is the wear of the electrodes, but contamination on the connecting surfaces can also occur. This leads to increasing downtime of the production lines. The aim was to reproduce the test results of resistance projection welding by laser beam welding. TRUMPF TruLaser Station 5004 type solid state laser and argon gas protection of the components have been applied. The main advantage of this welding method is that there is no direct contact between the welding tool and the components to be welded. A self-developed clamping system has been used to positioning and fixing the copper cables at laser beam welding. The laser-welded joints have been tested by the same destructive and non-destructive methods as the resistance-welded samples, so that the test result could have been comparable. The results will be evaluated and summarized.
Developments in copper to copper micro-welding technologies
Entwicklungen bei den Mikroschweißtechnologien für Kupfer zu Kupfer
2012
5 Seiten, 9 Bilder, 3 Tabellen, 20 Quellen
Conference paper
English
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