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<p>The study focused on the weldability and joint performance of various coatings, specifically Ni, Ag and Sn. Additionally, it investigated the formation of joints and defects in Cu plates using coatings, along with a fractographic analysis of coated joints. Experimental evaluation comprised of tensile testing, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), microhardness testing, X-ray diffraction (XRD), thermography analysis and electrical resistance measurements to assess mechanical properties and structural integrity of joints. Among the tested joints, Ag-clad Cu plate-Al wire joint demonstrated superior performance, exhibiting the highest tensile strength, optimal microstructure and favorable elemental composition. Ag coating layer has a substantial influence on the quality of microstructure formation. Under optimal conditions (e.g., P = 180&#xa0;kPa, Amp = 45% and W.E = 1600&#xa0;J), Ag coating layer results in a smooth and uniform interface. Furthermore, it minimizes the formation of intermetallic compound (IMC). Electrical resistance of Cu plate-Al wire, Ni-clad Cu plate-Al wire and Ag-clad Cu plate-Al wire are 0.018&#xa0;mΩ, 0.008&#xa0;mΩ and 0.005&#xa0;mΩ respectively. Ag coating layer facilitates the development of a uniform intermetallic compound (IMC) layer at interface between Al wire and Cu plate, increasing the mechanical properties of welded joints. Besides, it promotes effective deformation within the interfacial microstructure which helps to reduce oxide layers and mitigate corrosion.</p>

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Long-term Performance Analysis of Welded Joints Using Ultrasonic Wire Harness in Addition with Ni(Cu), Ag(Cu) and Sn(Cu) Clads

  • 期刊论文

  • 发表日期：

    2025年3月13日

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  • Lun Zhao,
  • Yingzhong Tian,
  • Hafiz Abdul Saboor,
  • Xuanlin Ye,
  • Zeshan Abbas,
  • Lin Sen,
  • Saad Saleem Khan,
  • Stephen Larkin

摘要

The study focused on the weldability and joint performance of various coatings, specifically Ni, Ag and Sn. Additionally, it investigated the formation of joints and defects in Cu plates using coatings, along with a fractographic analysis of coated joints. Experimental evaluation comprised of tensile testing, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), microhardness testing, X-ray diffraction (XRD), thermography analysis and electrical resistance measurements to assess mechanical properties and structural integrity of joints. Among the tested joints, Ag-clad Cu plate-Al wire joint demonstrated superior performance, exhibiting the highest tensile strength, optimal microstructure and favorable elemental composition. Ag coating layer has a substantial influence on the quality of microstructure formation. Under optimal conditions (e.g., P = 180 kPa, Amp = 45% and W.E = 1600 J), Ag coating layer results in a smooth and uniform interface. Furthermore, it minimizes the formation of intermetallic compound (IMC). Electrical resistance of Cu plate-Al wire, Ni-clad Cu plate-Al wire and Ag-clad Cu plate-Al wire are 0.018 mΩ, 0.008 mΩ and 0.005 mΩ respectively. Ag coating layer facilitates the development of a uniform intermetallic compound (IMC) layer at interface between Al wire and Cu plate, increasing the mechanical properties of welded joints. Besides, it promotes effective deformation within the interfacial microstructure which helps to reduce oxide layers and mitigate corrosion.