Effects of ultrasonic welding parameters for solar collector applications

Abstract

Abstract Today, ultrasonic welding is used in many different areas due to ease of application compared to other welding methods. Computer, electric, automotive and aerospace industries are the leading areas for these applications. With its ability to easily join materials like Al, Cu, Ni, ultrasonic welding has become a preferred method for use in the welding of solar collectors which are components in solar energy systems. The system parameters for welding solar collectors must of course be adjusted according to the properties of the materials used so that the heat transfer between specimens is not affected. In this study, the selective coated plate and the heat carrier pipes of solar collectors were welded using ultrasonic seam welding, and the optimum welding parameters were determined according to the Cu-DHP copper alloy used. For this purpose, copper specimens were welded using welding speeds of 4, 8, 12 and 16 m × min−1 and amplitudes of 4, 5 and 6 μm, while pressure and frequency values were fixed. The shear strength values of these welded specimens were calculated, and images of the weld areas were obtained with the help of a scanning electron microscope. Through hardness measurements made on the interfacial region of the welds, it was concluded that optimal welding performance was obtained at an amplitude of 4 μm and a welding speed of 12 m × min−1. At these parameters, a mean shear strength value of 0.1386 MPa and a mean hardness value of 112 HV were measured.