{"id":457496,"date":"2024-10-20T09:51:35","date_gmt":"2024-10-20T09:51:35","guid":{"rendered":"https:\/\/pdfstandards.shop\/product\/uncategorized\/bs-en-iec-60352-92024\/"},"modified":"2024-10-26T18:19:21","modified_gmt":"2024-10-26T18:19:21","slug":"bs-en-iec-60352-92024","status":"publish","type":"product","link":"https:\/\/pdfstandards.shop\/product\/publishers\/bsi\/bs-en-iec-60352-92024\/","title":{"rendered":"BS EN IEC 60352-9:2024"},"content":{"rendered":"

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.<\/p>\n

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2<\/td>\nundefined <\/td>\n<\/tr>\n
5<\/td>\nAnnex ZA (normative)Normative references to international publicationswith their corresponding European publications <\/td>\n<\/tr>\n
8<\/td>\nEnglish
CONTENTS <\/td>\n<\/tr>\n
13<\/td>\nFOREWORD <\/td>\n<\/tr>\n
15<\/td>\nINTRODUCTION <\/td>\n<\/tr>\n
16<\/td>\n1 Scope
2 Normative references <\/td>\n<\/tr>\n
18<\/td>\n3 Terms and definitions <\/td>\n<\/tr>\n
19<\/td>\nFigures
Figure 1 \u2013 Ultrasonic welding machine designed to make splicesbetween at least two wires <\/td>\n<\/tr>\n
20<\/td>\nFigure 2 \u2013 Ultrasonically welded splice of two wires protected by a shrinking tube
Figure 3 \u2013 Top view of an ultrasonically welded wire on a terminal <\/td>\n<\/tr>\n
21<\/td>\nFigure 4 \u2013 Side view of an ultrasonically welded wire on a terminal
Figure 5 \u2013 Ultrasonically welded end compaction <\/td>\n<\/tr>\n
22<\/td>\n4 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 \u2013 Ultrasonically welded end splice connection <\/td>\n<\/tr>\n
23<\/td>\nFigure 7 \u2013 Welding zone (1) for two stripped wires withheat shrink tubing (2) for insulation
Figure 8 \u2013 Ultrasonically welded end compaction
Figure 9 \u2013 Ultrasonically welded end splice
Figure 10 \u2013 Ultrasonically welded inline splice Cu-Al
Figure 11 \u2013 Ultrasonically welded inline splice Cu-Cu <\/td>\n<\/tr>\n
24<\/td>\nFigure 12 \u2013 Example 1 of ultrasonic welding on terminals
Figure 13 \u2013 Example 2 of ultrasonic welding on terminals
Figure 14 \u2013 Example 3 of ultrasonic welding on terminals
Figure 15 \u2013 Example 4 of ultrasonic welding on terminals
Figure 16 \u2013 Example of multiple wires welded to one terminals <\/td>\n<\/tr>\n
25<\/td>\n5.2 General requirements <\/td>\n<\/tr>\n
26<\/td>\n5.3 Influence of wire length for welds at the other end of terminal connections
5.4 Design requirements
Figure 17 \u2013 Illustration of the conductor length (3)between terminal (2) and welded package (1)
Figure 18 \u2013 Cross-sectional view of ultrasonic propagation through the sonotrode in the welding room, against passive surfaces with and without gap between the tools <\/td>\n<\/tr>\n
27<\/td>\nFigure 19 \u2013 Cross-sectional view of recommended asymmetrical insertion for the individual conductors above the sonotrode in the welding room
Figure 20 \u2013 Cross-sectional alternative view of the recommended asymmetrical insertion for the individual conductors above the sonotrode <\/td>\n<\/tr>\n
28<\/td>\n5.5 Mechanical and electrical protection of the weld package
Figure 21 \u2013 Insulation measures at the inline splicefrom one conductor to several conductors
Figure 22 \u2013 Insulation measures at the feed-inline splicewith several conductors on both sides
Tables
Table 1 \u2013 Ultrasonically welded packages suggested values <\/td>\n<\/tr>\n
29<\/td>\n5.6 Conductor combinations \u2013 requirements
5.7 Compaction ratio of ultrasonically welded connections
Figure 23 \u2013 Insulation measures at the end splice with several conductors (end sealed)
Table 2 \u2013 Conductor combinations <\/td>\n<\/tr>\n
30<\/td>\nFigure 24 \u2013 Cu-wire compaction ratio from strong to weak layout
Figure 25 \u2013 Conductor before and after welding <\/td>\n<\/tr>\n
31<\/td>\n6 Specimens
6.1 General
6.2 Type A1 or A2 specimen
6.3 Type B1 or B2 specimen
Figure 26 \u2013 Type A1 specimen
Figure 27 \u2013 Type A2 specimen <\/td>\n<\/tr>\n
32<\/td>\n6.4 Type C specimen
Figure 28 \u2013 Type B1 specimen, inline splice with two wires type 1 and type 2
Figure 29 \u2013 Type B2 specimen
Figure 30 \u2013 Type C specimen, end-splice connection with type 3 and type 4 wires <\/td>\n<\/tr>\n
33<\/td>\n6.5 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 \u2013 Type D specimen at the wire to terminal connection <\/td>\n<\/tr>\n
34<\/td>\n7.2.2 Magnification aids (visual optical inspection, VOI)
7.2.3 Visual inspection of the ultrasonic splice welding
Table 3 \u2013 Magnification suggestions for visual inspection
Table 4 \u2013 Example of good welds for end splices and inline splices <\/td>\n<\/tr>\n
35<\/td>\n7.2.4 Visual inspection of ultrasonically welded wire to terminal
Table 5 \u2013 Representation of error characteristics for end splices and inline splices <\/td>\n<\/tr>\n
36<\/td>\nFigure 32 \u2013 Measurement of the ultrasonic weld height
Figure 33 \u2013 Measurement of the ultrasonic weld width (2)
Table 6 \u2013 Valid features of ultrasonically welded wire on terminal <\/td>\n<\/tr>\n
37<\/td>\n7.3 Mechanical tests
7.3.1 Bending test inline splice
Table 7 \u2013 Non-valid features of ultrasonically welded wire on terminal <\/td>\n<\/tr>\n
38<\/td>\n7.3.2 Bending test on ultrasonically welded wire to terminal
7.3.3 Peel test of the splice
Figure 34 \u2013 Bending test setup schematic illustration
Figure 35 \u2013 Terminal bending test setup schematic illustration <\/td>\n<\/tr>\n
39<\/td>\nFigure 36 \u2013 Test setup for peel tests
Table 8 \u2013 Peel force values for ultrasonically welded splices of copper wires <\/td>\n<\/tr>\n
40<\/td>\nTable 9 \u2013 Peel force values for ultrasonically welded splices of aluminium wires <\/td>\n<\/tr>\n
41<\/td>\n7.3.4 Peel tests of the terminal-welded package
Figure 37 \u2013 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 \u2013 Peel force values for ultrasonically welded copper wires on terminals <\/td>\n<\/tr>\n
42<\/td>\n7.3.5 Pull-out force tests on ultrasonic splice-welded connections
Figure 38 \u2013 Test setup for pull-out force test
Table 11 \u2013 Peel force values for ultrasonically welded aluminium wires on terminals <\/td>\n<\/tr>\n
43<\/td>\nTable 12 \u2013 Pull-out force values for ultrasonically welded splices of copper wires <\/td>\n<\/tr>\n
44<\/td>\n7.3.6 Pull-out force tests of ultrasonically welded wire-to-terminal connections
Table 13 \u2013 Pull-out force values for ultrasonically welded splices of aluminium wires <\/td>\n<\/tr>\n
45<\/td>\nFigure 39 \u2013 Test setup for the pull-out force test on welds with electrical conductors on terminal
Table 14 \u2013 Pull-out force values for ultrasonically welded copper wires on terminals <\/td>\n<\/tr>\n
46<\/td>\nTable 15 \u2013 Dependence of package width on conductor cross-sectional areafor copper wires (recommended)
Table 16 \u2013 Pull-out force values for ultrasonically welded aluminium wires on terminals <\/td>\n<\/tr>\n
47<\/td>\n7.3.7 Vibration test of ultrasonically welded splice connections
Figure 40 \u2013 Test setup for vibration test of the splice
Table 17 \u2013 Dependence of package width on conductor cross-sectional areafor aluminium wires (recommended) <\/td>\n<\/tr>\n
48<\/td>\n7.3.8 Vibration test of ultrasonically welded wire-to-terminal connections
Figure 41 \u2013 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 \u2013 Vibration test (sinusoidal) parameters of ultrasonically welded splice connections <\/td>\n<\/tr>\n
49<\/td>\n7.3.9 Compaction force test of end splices
Figure 42 \u2013 Aluminium single wire end splice (wire end compacted)
Figure 44 \u2013 Medium copper single wire end splice (wire end compacted)
Figure 45 \u2013 Large copper single wire end splice (wire end compacted)
Figure 46 \u2013 Examples of test clamps of different sizes <\/td>\n<\/tr>\n
50<\/td>\n7.4 Microsection image inspections
Figure 47 \u2013 Example 1 of a valid microsection imageof ultrasonically welded copper strands
Table 19 \u2013 Requirements for single end compaction test <\/td>\n<\/tr>\n
51<\/td>\n7.5 Electrical tests
7.5.1 Voltage drop of the through or end splice (resistance)
Figure 48 \u2013 Example 2 of a valid microsection imageof ultrasonically welded copper strands
Figure 49 \u2013 Example 3 of a valid microsection imageof ultrasonically welded copper strands
Figure 50 \u2013 Set-up for measurement at the splice (from 2 to 20 wires)
Figure 51 \u2013 Measurements of reference wires type 1 and type 2 <\/td>\n<\/tr>\n
52<\/td>\n7.5.2 Voltage drop of the wire-to-terminal connection (resistance)
Figure 52 \u2013 Setup for voltage drop measurement (U1), at the terminal weld connections <\/td>\n<\/tr>\n
53<\/td>\n7.5.3 Current-carrying capacity
Figure 53 \u2013 Voltage drop measurement (U2) with the same reference wire (1) <\/td>\n<\/tr>\n
54<\/td>\nFigure 54 \u2013 Setup for temperature rise measurements at current load <\/td>\n<\/tr>\n
55<\/td>\n7.5.4 Insulation resistance
7.5.5 Voltage proof
Figure 55 \u2013 Temperature chamber with valve opening for current-load measurements <\/td>\n<\/tr>\n
56<\/td>\n8 Climatic tests
8.1 General information on climatic tests
8.2 Rapid change of temperature
Figure 56 \u2013 Diagram of dielectric voltage withstanding (voltage proof) test
Table 20 \u2013 Test voltages for voltage proof test <\/td>\n<\/tr>\n
57<\/td>\n8.3 Dry heat
8.4 Cold
8.5 Damp heat <\/td>\n<\/tr>\n
58<\/td>\n8.6 Climatic sequence
8.7 Flowing mixed gas corrosion <\/td>\n<\/tr>\n
59<\/td>\n9 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 \u2013 Test group P0 \u2013 Initial inspection <\/td>\n<\/tr>\n
60<\/td>\n10.2 Test schedule B (class B product, see 9.3)
10.2.1 General
10.2.2 Mechanical tests of test schedule B
Table 22 \u2013 Test group P1 \u2013 Bending test <\/td>\n<\/tr>\n
61<\/td>\n10.2.3 Electrical tests of test schedule B
Table 23 \u2013 Test group P2 \u2013 Peel test according to ISO 10447
Table 24 \u2013 Test group P3 \u2013 Pull-out force test
Table 25 \u2013 Test group P4 \u2013 Compaction-force for single wire end-splices
Table 26 \u2013 Test group P6 \u2013 Voltage drop (resistance)
Table 27 \u2013 Test group P7 \u2013 Insulation resistance <\/td>\n<\/tr>\n
62<\/td>\n10.2.4 Microsection tests of test schedule B
10.3 Test schedule C (class C products, see 9.4)
10.3.1 General
Table 28 \u2013 Test group P10 \u2013 Microsection
Table 29 \u2013 Test group P0 \u2013 Initial inspection <\/td>\n<\/tr>\n
63<\/td>\n10.3.2 Mechanical tests according to test schedule C
10.3.3 Electrical tests according to test schedule C
Table 30 \u2013 Test group P2 \u2013 Peel tests
Table 31 \u2013 Test group P3 \u2013 Pull-out force tests
Table 32 \u2013 Test group P4 \u2013 Compaction-force test for single wire end-splices
Table 33 \u2013 Test group P5 \u2013 Vibration test (sinusoidal)
Table 34 \u2013 Test group P6 \u2013 Voltage drop (resistance) <\/td>\n<\/tr>\n
64<\/td>\n10.3.4 Microsection of test schedule C
10.3.5 Climatic test for test schedule C
Table 35 \u2013 Test group P7 \u2013 Insulation resistance
Table 36 \u2013 Test group P8 \u2013 Current-carrying capacity
Table 37 \u2013 Test group P10 \u2013 Microsection
Table 38 \u2013 Test group P11 \u2013 Climatic tests <\/td>\n<\/tr>\n
65<\/td>\n11 Additional applicable test groups (if required)
11.1 Dry heat test and voltage proof
11.2 Corrosion
Table 39 \u2013 Test group P9 \u2013 Voltage proof
Table 40 \u2013 Test group P12 \u2013 Corrosion <\/td>\n<\/tr>\n
66<\/td>\nFigure 57 \u2013 Test schedule A <\/td>\n<\/tr>\n
67<\/td>\nFigure 58 \u2013 Test Schedule B <\/td>\n<\/tr>\n
68<\/td>\nFigure 59 \u2013 Test schedule C part 1 <\/td>\n<\/tr>\n
69<\/td>\nFigure 60 \u2013 Test schedule C part 2 <\/td>\n<\/tr>\n
70<\/td>\nAnnex A (informative)Practical guidance
A.1 Ultrasonic welding system
A.2 Storage conditions and processing conditions
Figure A.1 \u2013 Ultrasonic welding process: 1) longitudinal, 2) torsional <\/td>\n<\/tr>\n
71<\/td>\nA.3 Processing technique
A.3.1 General tooling technology requirements
A.3.2 Monitoring <\/td>\n<\/tr>\n
72<\/td>\nBibliography <\/td>\n<\/tr>\n<\/table>\n","protected":false},"excerpt":{"rendered":"

Solderless connections – Ultrasonically welded connections. General requirements, test methods and practical guidance<\/b><\/p>\n\n\n\n\n
Published By<\/td>\nPublication Date<\/td>\nNumber of Pages<\/td>\n<\/tr>\n
BSI<\/b><\/a><\/td>\n2024<\/td>\n74<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n","protected":false},"featured_media":457506,"template":"","meta":{"rank_math_lock_modified_date":false,"ep_exclude_from_search":false},"product_cat":[508,2641],"product_tag":[],"class_list":{"0":"post-457496","1":"product","2":"type-product","3":"status-publish","4":"has-post-thumbnail","6":"product_cat-29-120-20","7":"product_cat-bsi","9":"first","10":"instock","11":"sold-individually","12":"shipping-taxable","13":"purchasable","14":"product-type-simple"},"_links":{"self":[{"href":"https:\/\/pdfstandards.shop\/wp-json\/wp\/v2\/product\/457496","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/pdfstandards.shop\/wp-json\/wp\/v2\/product"}],"about":[{"href":"https:\/\/pdfstandards.shop\/wp-json\/wp\/v2\/types\/product"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/pdfstandards.shop\/wp-json\/wp\/v2\/media\/457506"}],"wp:attachment":[{"href":"https:\/\/pdfstandards.shop\/wp-json\/wp\/v2\/media?parent=457496"}],"wp:term":[{"taxonomy":"product_cat","embeddable":true,"href":"https:\/\/pdfstandards.shop\/wp-json\/wp\/v2\/product_cat?post=457496"},{"taxonomy":"product_tag","embeddable":true,"href":"https:\/\/pdfstandards.shop\/wp-json\/wp\/v2\/product_tag?post=457496"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}