Abstract

This paper investigates the generation of debris during ultrasonic metal welding through integrated numerical and experimental modeling. A computational model was developed to simulate contact mechanics, frictional energy dissipation, and material deformation at the weld interface. The model successfully predicts particle detachment and ejection under varying process conditions. Experimental validation was performed on aluminum alloy specimens using high-speed imaging and post-weld analysis, revealing that debris morphology, size distribution, and generation rate are strongly influenced by vibration amplitude, clamping pressure, and weld time. Results show a three-fold increase in debris mass at high amplitude (40μm) and long weld time (2.0s) compared to baseline conditions, while increasing clamping pressure reduced debris formation by 40-50%. The numerical model demonstrated strong agreement with experimental measurements, with an average deviation of 12.3% in debris mass prediction. Statistical analysis confirmed significant differences (p<0.01) in debris generation across all parameter combinations, with ANOVA revealing that amplitude accounts for 67% of observed variance in debris mass. The study establishes a validated framework for predicting and mitigating particulate contamination in ultrasonic metal welding applications.

Keywords:Ultrasonic welding; Analytical model; Debris generation; Particle ejection; Particulate contamination