IEC 60352-9:2024

Overview

IEC 60352-9:2024 is an international standard published by the International Electrotechnical Commission (IEC) that specifies general requirements, test methods, and practical guidance for ultrasonically welded solderless connections. This standard focuses on connections made by ultrasonic welding, a cold friction welding technique that uses high-frequency ultrasonic vibrations to join conductor materials without heat, solder, or flux. Ultrasonic welding offers a reliable, cost-effective, and efficient method for creating strong metal-to-metal connections, especially useful for electrical conductors such as copper and aluminum wires.

The document covers ultrasonically welded connections for stranded or flexible copper, copper alloys, aluminum, and aluminum alloys wires with cross-sectional areas ranging from 0.08 mm² to 160 mm², with bundles not exceeding 200 mm². It also provides essential technical data, qualification test procedures, and recommendations to ensure consistent and reliable electrical performance under various environmental conditions.

Key Topics

1. Scope & Materials

• Standard applies to ultrasonic welding of stranded and flexible conductor wires (class 2, 5, and 6 per IEC 60228).
• Covers copper, copper alloys, aluminum, and aluminum alloys.
• Defines cross-sectional area limits for individual wires and wire bundles.
• Addresses material surface coatings and compatibility of conductor combinations.

2. Ultrasonic Welding Requirements

• General welding parameters and design requirements to guarantee weld integrity.
• Influence of conductor length and asymmetrical insertion on weld quality.
• Mechanical and electrical protection of weld packages, including insulation techniques.
• Standards for compaction ratios essential for weld strength.

3. Test Methods

• Comprehensive mechanical testing such as bending, peel, pull-out force, and vibration tests.
• Electrical testing including voltage drop, insulation resistance, current-carrying capacity, and voltage proof tests.
• Visual optical inspections and microsection analysis to assess quality and internal structure of welds.
• Climatic and environmental tests like rapid temperature changes, dry heat, damp heat, and corrosion resistance to simulate real-world application durability.

4. Product Classification & Test Schedules

• Defines product classes (A, B, C) based on application and performance requirements.
• Specifies tailored test schedules for each class to ensure compliance and reliability certification.

5. Practical Guidance

• Recommendations on ultrasonic welding system setup and tooling technology.
• Best practices on storage, handling, and processing conditions.
• Guidance on monitoring and quality control during production.

Applications

Ultrasonic welding covered by IEC 60352-9:2024 is increasingly adopted in multiple industries due to its precision, strong bonds, and efficient processing:

• Automotive Industry: Used for wiring harnesses, electrical connections, and sensor assemblies requiring robust, solderless joints.
• Electronics Manufacturing: Enables high-density wiring and terminal connections without thermal damage to sensitive components.
• Furniture Production: Facilitates assembly of electrical components and embedded wiring systems.
• Medical Device Manufacturing: Provides contamination-free, reliable connections critical to device safety and performance.
• General Electrical Engineering: Applicable for power cables, control wiring, and telecommunication assemblies.

The standard ensures ultrasonically welded connections meet strict mechanical and electrical requirements for safety, durability, and performance across these varied sectors.

Related Standards

• IEC 60228: Classifies conductor types, critical for defining wire flexibility and compatibility in ultrasonic welding.
• ISO 4063-41: International classification of welding processes, including ultrasonic welding.
• Other parts of IEC 60352 series cover different solderless connection methods for electrical wiring systems.
• Industry-specific standards that complement IEC 60352-9 for device-specific wiring and terminal connection requirements.

Keywords: IEC 60352-9, ultrasonic welding, solderless connections, electrical wiring standard, ultrasonically welded connections, ultrasonic welding test methods, copper wire welding, aluminum wire connections, industrial welding standards, ultrasonic splice welding, electrical connection quality, welding process guidelines, ultrasonic welding applications, international electrotechnical standards.