A Study of Embedment and Other Metallurgical and Mechanical Characteristics of Cross-Wire Resistance Welds 670218

An investigation was performed to evaluate the cross-wire resistance welded joints used in welded electronic assemblies for aerospace applications. Mechanical strength and reproducibility of strength were determined for several alloy combinations by performing single torsion-shear tests in a pneumatically operated pull testing machine. A metallographic investigation was performed in order to determine the type of bonding and the degree of mutual embedment resulting from the welding operation.
Material combinations investigated were Nickel 200 interconnect welded to itself, Kovar, Alloy 180, and Dumet; and Alloy 180 interconnect welded to itself, Kovar, and Dumet. Strength, embedment, and consistency data indicate that an optimum degree of embedment exists for each combination of materials. For the material combinations studied, the optimum embedment was found to be between 10 and 25 percent of the wire diameter.


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