Ultrasonic Energy Welds Beryllium Copper Spring to Copper Frame: Part 3 Ultrasonic metal welding provides a sound solution to a productionproblem with superior performance, improved throughput and reducedmaintenance. W.L. Gore & Associates, Inc. improves its competitiveadvantage by reducing 'Cost of Goods Sold'
After gathering process data, upper and lower control limits were calculated for weld time and peak weld power. Once statistical limits were set the system was capable of alerting manufacturing personnel of a changes in the process.
This process data is exportable via the controller's RS232 port. Moreover, since the Intelligent Controller stores the last fifty (50) sets of weld data, the quality department can collect process data at random intervals or program the system, at predetermined intervals, to send the data to a printer or computer. Utilization of maintenance and parts counters helps to schedule preventive maintenance as well as prevent over-production.
"Simply stated, it's great," Nahrgang said, "With the ultrasonic system, quality is exceptional, throughput is up and unscheduled down time is eliminated. Additionally, with the quality monitoring features the assembly personnel no longer worry about missing contacts due to an assembly system misfeed."
Summary (Success through Partnership)
Ultrasonic welding of Beryllium Copper to Copper has been shown to be efficient and effective as demonstrated by this and similar applications. The problems of tough oxides, high thermal conductivity, high electrical conductivity, sensitivity to annealing of electromechanical springs, weld splatter and electrode maintenance become non issues when the diffusion type ultrasonic welding process is utilized.
The problems associated with pre and postweld cleaning, fluxes, solders, and high energy costs are eliminated as well. Furthermore, AmTech ultrasonic welding equipment is capable of monitoring the process for excessive variation in weld time, weld power, component pre-height and assembly post-weld height.
Applications This application by Gore involves the welding of a gold plated BeCu contact to a Cu frame for an electrical connector. The female BeCu spring contact provides the excellent mechanical properties required to make a reliable connection with a male pin/ header contact. Welding the BeCu to the Cu frame reduced cost since the BeCu spring is only required at the electrical interface. The ultrasonic welding process provides a fast, reliable, low cost joint with the lowest electrical resistance possible. (This application was previously performed via resistance welding).
This application by TRW Automotive involves the welding of a stranded Cu wire to a BeCu spring contact for an automotive horn switch assembly. The BeCu spring contact provides the excellent mechanical properties required to make a reliable horn switch connection. Welding the stranded Cu wire to the BeCu spring reduced cost since the BeCu spring is only required at the electrical interface. The ultrasonic welding process provides a fast, reliable, low cost joint with the lowest electrical resistance possible. (This application was previously performed via soldering).
This application by Eaton - Commercial Controls Division involves the welding of a BeCu contact to a Brass terminal frame for an electrical switch. The BeCu spring contact provides the excellent mechanical properties required to make a reliable switch connection. Welding the BeCu to the Brass terminal frame reduced cost since the BeCu spring is only required at the electrical interface. The ultrasonic welding process provides a fast, reliable, low cost joint with the lowest electrical resistance possible.
Excerpted from "Ultrasonic Energy Welds Copper to Aluminum", Welding Journal, January 1997
This application by Gore involves the welding of a gold plated BeCu contact to a Cu frame for an electrical connector. The female BeCu spring contact provides the excellent mechanical properties required to make a reliable connection with a male pin/ header contact. Welding the BeCu to the Cu frame reduced cost since the BeCu spring is only required at the electrical interface. The ultrasonic welding process provides a fast, reliable, low cost joint with the lowest electrical resistance possible. (This application was previously performed via resistance welding). 
This application by TRW Automotive involves the welding of a stranded Cu wire to a BeCu spring contact for an automotive horn switch assembly. The BeCu spring contact provides the excellent mechanical properties required to make a reliable horn switch connection. Welding the stranded Cu wire to the BeCu spring reduced cost since the BeCu spring is only required at the electrical interface. The ultrasonic welding process provides a fast, reliable, low cost joint with the lowest electrical resistance possible. (This application was previously performed via soldering). 
This application by Eaton - Commercial Controls Division involves the welding of a BeCu contact to a Brass terminal frame for an electrical switch. The BeCu spring contact provides the excellent mechanical properties required to make a reliable switch connection. Welding the BeCu to the Brass terminal frame reduced cost since the BeCu spring is only required at the electrical interface. The ultrasonic welding process provides a fast, reliable, low cost joint with the lowest electrical resistance possible.
