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BS EN IEC 60352-9:2024

BS EN IEC 60352-9:2024

$215.11

Solderless connections – Ultrasonically welded connections. General requirements, test methods and practical guidance

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BSI 2024 74
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IEC 60352-9:2024 provides guidelines for welding and testing of ultrasonically welded connections and includes requirements, tests and practical guidance information. Ultrasonic welding is a form of cold friction welding that is becoming increasingly popular in many industries. This type of welding uses ultrasonic vibration to join materials together, creating a bond that is both strong and reliable. Ultrasonic welding has been identified as a process in ISO 4063-41 by the International Organization for Standardization (ISO). The process of ultrasonic welding relies on high frequency ultrasound waves being used to create frictional heat at the connection point. High temperature is not required for this special method of welding, making it one of the most cost-effective ways to join two materials together. It also requires fewer steps than traditional methods, meaning it can be completed quickly and with minimal resources. Ultrasonic welding has been around for decades but only recently has become more widely utilized due to advances in technology and its availability at lower cost. It can be used on many different materials including plastics, rubbers, metals, textiles, and composites. Due to its precision and strong bonds it creates, it has become extremely popular in manufacturing processes such as automotive industry, electronics industry, furniture production and even medical device production. This document covers ultrasonically welded connections made with stranded or flexible wires (class 2, 5 or 6 per IEC 60228) of copper or copper alloy, as well as of aluminium or aluminium alloy. These welded metal-to-metal connections shall employ wires with cross-sectional area of 0,08 mm2 to 160 mm2 and shall not exceed a total cross-sectional area, in case of wire bundle, of 200 mm2. For aluminium or aluminium alloy wires, the minimum required cross-sectional area is 2,5 mm2. Additionally, information on materials, data from industrial experience and test procedures are included to ensure electrically stable connections under prescribed environmental conditions. Lastly, this document aims to achieve comparable results when using ultrasonic welding equipment with similar performance and specifications as specified by the termination manufacturer.

PDF Catalog

PDF Pages PDF Title
2 undefined
5 Annex ZA (normative)Normative references to international publicationswith their corresponding European publications
8 English
CONTENTS
13 FOREWORD
15 INTRODUCTION
16 1 Scope
2 Normative references
18 3 Terms and definitions
19 Figures
Figure 1 – Ultrasonic welding machine designed to make splicesbetween at least two wires
20 Figure 2 – Ultrasonically welded splice of two wires protected by a shrinking tube
Figure 3 – Top view of an ultrasonically welded wire on a terminal
21 Figure 4 – Side view of an ultrasonically welded wire on a terminal
Figure 5 – Ultrasonically welded end compaction
22 4 Wire and terminal information
4.1 Conductor materials
4.2 Conductor surface coating
5 Requirements for ultrasonic welding
5.1 Examples of ultrasonically welded connections
Figure 6 – Ultrasonically welded end splice connection
23 Figure 7 – Welding zone (1) for two stripped wires withheat shrink tubing (2) for insulation
Figure 8 – Ultrasonically welded end compaction
Figure 9 – Ultrasonically welded end splice
Figure 10 – Ultrasonically welded inline splice Cu-Al
Figure 11 – Ultrasonically welded inline splice Cu-Cu
24 Figure 12 – Example 1 of ultrasonic welding on terminals
Figure 13 – Example 2 of ultrasonic welding on terminals
Figure 14 – Example 3 of ultrasonic welding on terminals
Figure 15 – Example 4 of ultrasonic welding on terminals
Figure 16 – Example of multiple wires welded to one terminals
25 5.2 General requirements
26 5.3 Influence of wire length for welds at the other end of terminal connections
5.4 Design requirements
Figure 17 – Illustration of the conductor length (3)between terminal (2) and welded package (1)
Figure 18 – Cross-sectional view of ultrasonic propagation through the sonotrode in the welding room, against passive surfaces with and without gap between the tools
27 Figure 19 – Cross-sectional view of recommended asymmetrical insertion for the individual conductors above the sonotrode in the welding room
Figure 20 – Cross-sectional alternative view of the recommended asymmetrical insertion for the individual conductors above the sonotrode
28 5.5 Mechanical and electrical protection of the weld package
Figure 21 – Insulation measures at the inline splicefrom one conductor to several conductors
Figure 22 – Insulation measures at the feed-inline splicewith several conductors on both sides
Tables
Table 1 – Ultrasonically welded packages suggested values
29 5.6 Conductor combinations – requirements
5.7 Compaction ratio of ultrasonically welded connections
Figure 23 – Insulation measures at the end splice with several conductors (end sealed)
Table 2 – Conductor combinations
30 Figure 24 – Cu-wire compaction ratio from strong to weak layout
Figure 25 – Conductor before and after welding
31 6 Specimens
6.1 General
6.2 Type A1 or A2 specimen
6.3 Type B1 or B2 specimen
Figure 26 – Type A1 specimen
Figure 27 – Type A2 specimen
32 6.4 Type C specimen
Figure 28 – Type B1 specimen, inline splice with two wires type 1 and type 2
Figure 29 – Type B2 specimen
Figure 30 – Type C specimen, end-splice connection with type 3 and type 4 wires
33 6.5 Type D specimen
7 Tests
7.1 General information about tests
7.1.1 General conditions for product qualification tests
7.1.2 Pre-conditioning
7.1.3 Recovery
7.2 Visual optical inspection (VOI) with dimensional checks
7.2.1 General
Figure 31 – Type D specimen at the wire to terminal connection
34 7.2.2 Magnification aids (visual optical inspection, VOI)
7.2.3 Visual inspection of the ultrasonic splice welding
Table 3 – Magnification suggestions for visual inspection
Table 4 – Example of good welds for end splices and inline splices
35 7.2.4 Visual inspection of ultrasonically welded wire to terminal
Table 5 – Representation of error characteristics for end splices and inline splices
36 Figure 32 – Measurement of the ultrasonic weld height
Figure 33 – Measurement of the ultrasonic weld width (2)
Table 6 – Valid features of ultrasonically welded wire on terminal
37 7.3 Mechanical tests
7.3.1 Bending test inline splice
Table 7 – Non-valid features of ultrasonically welded wire on terminal
38 7.3.2 Bending test on ultrasonically welded wire to terminal
7.3.3 Peel test of the splice
Figure 34 – Bending test setup schematic illustration
Figure 35 – Terminal bending test setup schematic illustration
39 Figure 36 – Test setup for peel tests
Table 8 – Peel force values for ultrasonically welded splices of copper wires
40 Table 9 – Peel force values for ultrasonically welded splices of aluminium wires
41 7.3.4 Peel tests of the terminal-welded package
Figure 37 – Test setup for the peel test, fixation (4), side fixations with a protrusion of 1,0 mm each on the terminal surface, ultrasonically welded package (1), terminal (3)
Table 10 – Peel force values for ultrasonically welded copper wires on terminals
42 7.3.5 Pull-out force tests on ultrasonic splice-welded connections
Figure 38 – Test setup for pull-out force test
Table 11 – Peel force values for ultrasonically welded aluminium wires on terminals
43 Table 12 – Pull-out force values for ultrasonically welded splices of copper wires
44 7.3.6 Pull-out force tests of ultrasonically welded wire-to-terminal connections
Table 13 – Pull-out force values for ultrasonically welded splices of aluminium wires
45 Figure 39 – Test setup for the pull-out force test on welds with electrical conductors on terminal
Table 14 – Pull-out force values for ultrasonically welded copper wires on terminals
46 Table 15 – Dependence of package width on conductor cross-sectional areafor copper wires (recommended)
Table 16 – Pull-out force values for ultrasonically welded aluminium wires on terminals
47 7.3.7 Vibration test of ultrasonically welded splice connections
Figure 40 – Test setup for vibration test of the splice
Table 17 – Dependence of package width on conductor cross-sectional areafor aluminium wires (recommended)
48 7.3.8 Vibration test of ultrasonically welded wire-to-terminal connections
Figure 41 – Setup for vibration test of the ultrasonically welded package (1), vibration table (5), fixtures (2), terminal (4), reference wire with counter-contact connector (7)
Table 18 – Vibration test (sinusoidal) parameters of ultrasonically welded splice connections
49 7.3.9 Compaction force test of end splices
Figure 42 – Aluminium single wire end splice (wire end compacted)
Figure 44 – Medium copper single wire end splice (wire end compacted)
Figure 45 – Large copper single wire end splice (wire end compacted)
Figure 46 – Examples of test clamps of different sizes
50 7.4 Microsection image inspections
Figure 47 – Example 1 of a valid microsection imageof ultrasonically welded copper strands
Table 19 – Requirements for single end compaction test
51 7.5 Electrical tests
7.5.1 Voltage drop of the through or end splice (resistance)
Figure 48 – Example 2 of a valid microsection imageof ultrasonically welded copper strands
Figure 49 – Example 3 of a valid microsection imageof ultrasonically welded copper strands
Figure 50 – Set-up for measurement at the splice (from 2 to 20 wires)
Figure 51 – Measurements of reference wires type 1 and type 2
52 7.5.2 Voltage drop of the wire-to-terminal connection (resistance)
Figure 52 – Setup for voltage drop measurement (U1), at the terminal weld connections
53 7.5.3 Current-carrying capacity
Figure 53 – Voltage drop measurement (U2) with the same reference wire (1)
54 Figure 54 – Setup for temperature rise measurements at current load
55 7.5.4 Insulation resistance
7.5.5 Voltage proof
Figure 55 – Temperature chamber with valve opening for current-load measurements
56 8 Climatic tests
8.1 General information on climatic tests
8.2 Rapid change of temperature
Figure 56 – Diagram of dielectric voltage withstanding (voltage proof) test
Table 20 – Test voltages for voltage proof test
57 8.3 Dry heat
8.4 Cold
8.5 Damp heat
58 8.6 Climatic sequence
8.7 Flowing mixed gas corrosion
59 9 Classification into product classes
9.1 General
9.2 Class A product
9.3 Class B product
9.4 Class C product
10 Test schedules
10.1 Test schedule A (class A products, see 9.2)
Table 21 – Test group P0 – Initial inspection
60 10.2 Test schedule B (class B product, see 9.3)
10.2.1 General
10.2.2 Mechanical tests of test schedule B
Table 22 – Test group P1 – Bending test
61 10.2.3 Electrical tests of test schedule B
Table 23 – Test group P2 – Peel test according to ISO 10447
Table 24 – Test group P3 – Pull-out force test
Table 25 – Test group P4 – Compaction-force for single wire end-splices
Table 26 – Test group P6 – Voltage drop (resistance)
Table 27 – Test group P7 – Insulation resistance
62 10.2.4 Microsection tests of test schedule B
10.3 Test schedule C (class C products, see 9.4)
10.3.1 General
Table 28 – Test group P10 – Microsection
Table 29 – Test group P0 – Initial inspection
63 10.3.2 Mechanical tests according to test schedule C
10.3.3 Electrical tests according to test schedule C
Table 30 – Test group P2 – Peel tests
Table 31 – Test group P3 – Pull-out force tests
Table 32 – Test group P4 – Compaction-force test for single wire end-splices
Table 33 – Test group P5 – Vibration test (sinusoidal)
Table 34 – Test group P6 – Voltage drop (resistance)
64 10.3.4 Microsection of test schedule C
10.3.5 Climatic test for test schedule C
Table 35 – Test group P7 – Insulation resistance
Table 36 – Test group P8 – Current-carrying capacity
Table 37 – Test group P10 – Microsection
Table 38 – Test group P11 – Climatic tests
65 11 Additional applicable test groups (if required)
11.1 Dry heat test and voltage proof
11.2 Corrosion
Table 39 – Test group P9 – Voltage proof
Table 40 – Test group P12 – Corrosion
66 Figure 57 – Test schedule A
67 Figure 58 – Test Schedule B
68 Figure 59 – Test schedule C part 1
69 Figure 60 – Test schedule C part 2
70 Annex A (informative)Practical guidance
A.1 Ultrasonic welding system
A.2 Storage conditions and processing conditions
Figure A.1 – Ultrasonic welding process: 1) longitudinal, 2) torsional
71 A.3 Processing technique
A.3.1 General tooling technology requirements
A.3.2 Monitoring
72 Bibliography

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BS EN IEC 60352-9:2024
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