Ultrasonic welding of soft polymer and metal: A preliminary study

Yuquan Meng, Dingyu Peng, Qasim Nazir, Gowtham Kuntumalla, Manjunath C. Rajagopal, Ho Chan Chang, Hanyang Zhao, Sreenath Sundar, Placid M. Ferreira, Sanjiv Sinha, Nenad Miljkovic, Srinivasa M. Salapaka, Chenhui Shao

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Joining soft polymers and metals is receiving increasing attention in both industry and academia to enable the manufacturing of innovative products. One motivation arises from the production of next-generation heat exchanges, the structure of which is primarily composed of polymers and metals. Waste heat coming from low temperature exhaust gas stream is significant in industries in the U.S. However, traditional heat exchangers that are available to recover heat in the presence of small temperature difference are large and costly, restricting the wide application of such heat exchangers. To address this challenge, a hybrid materials design is proposed to achieve a balance between thermal conductivity and mechanical strength. High quality requirement induced by the changing operating conditions necessitates a strong bonding between polymers and copper. In this research, the possibility of using ultrasonic welding, which is conventionally employed to join dissimilar or similar metal layers, is explored. Preliminary results from welding experiments and tensile shear tests reveal that two bonding modes exist in the welding of PET and copper. Furthermore, analysis of power signals collected during welding shows that one can potentially monitor and optimize welding processes using monitoring signals. It is concluded from this study that ultrasonic welding has excellent potential in joining soft polymers and metals. Future work is also discussed on the process improvement and mechanism investigation.

Original languageEnglish (US)
Title of host publicationProcesses; Materials
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791858752
DOIs
StatePublished - Jan 1 2019
EventASME 2019 14th International Manufacturing Science and Engineering Conference, MSEC 2019 - Erie, United States
Duration: Jun 10 2019Jun 14 2019

Publication series

NameASME 2019 14th International Manufacturing Science and Engineering Conference, MSEC 2019
Volume2

Conference

ConferenceASME 2019 14th International Manufacturing Science and Engineering Conference, MSEC 2019
CountryUnited States
CityErie
Period6/10/196/14/19

Keywords

  • Copper
  • Dissimilar Materials
  • Heat Exchanger
  • PET
  • Soft Polymer
  • Ultrasonic Welding

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

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  • Cite this

    Meng, Y., Peng, D., Nazir, Q., Kuntumalla, G., Rajagopal, M. C., Chang, H. C., Zhao, H., Sundar, S., Ferreira, P. M., Sinha, S., Miljkovic, N., Salapaka, S. M., & Shao, C. (2019). Ultrasonic welding of soft polymer and metal: A preliminary study. In Processes; Materials (ASME 2019 14th International Manufacturing Science and Engineering Conference, MSEC 2019; Vol. 2). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/MSEC2019-2938