Ultrasonic metal welding (UMW) is widely used in high-volume manufacturing, particularly lithium-ion battery assembly, due to its fast cycle time and ability to join thin or dissimilar materials. But the process is sensitive to variations in tooling, materials, and process conditions, and conventional quality control relies on destructive testing methods that are costly, time-consuming, and unsuitable for 100% inspection.
In this new paper, EWI Applications Engineer Amin Moghaddas evaluates acoustic emission (AE) sensors and microphones as a real-time, non-destructive alternative for monitoring UMW quality. Using welds produced under underweld, good weld, and overweld conditions representative of lithium-ion battery manufacturing, the study demonstrates strong classification accuracy across multiple acoustic sensing approaches, offering a practical path toward in-process quality monitoring on the factory floor.
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Topics explored in this paper include:
- How AE sensors and microphones can classify weld quality in real time
- Classification accuracy results across AE sensors of varying frequency ranges and non-contact microphone sensing
- Advanced methods used to correlate acoustic signals with weld quality
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To learn more, contact Amin Moghaddas, Applications Engineer, at [email protected].