This research study aims to investigate the mechanical and metallographical aspects of ultrasonic welding of Cu-Cu wires. Experimental trials have been conducted and observations have been recorded as a database that collates parametric, quality and strength aspects of various weldments. Destructive testing and metallurgical characterizations have been carried out to examine the strength and integrity of the weldment. The key focus of this research attempt is laid on determining and evaluating the factors that governs the strength of the weldment. Metallurgical characterizations reveal vital information on the weld integrity and the extent of grain distribution. Further, FEM is employed to understand the deformation and thermal aspects involved in Cu-Cu welding using ultrasonics. The numerical model may provide an insight into the thermal phenomenon governing the joining process and subsequently estimation of the impact. Response surface methodology is employed to identify the parametric interdependencies and subsequently determine the optimized range.
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