COMPREHENSIVE WELDABILITY ANALYSIS AND MORPHOLOGICAL- THERMAL INSIGHTS INTO ULTRASONIC WELDING OF ABS FOR ELECTRONICS APPLICATIONS

The use of ultrasonic welding for joining thermoplastic materials has also attracted much interest as a precise and efficient method. This study examines the application of ultrasonic welding in the production of casings for power circuits in battery chargers, utilising Acrylonitrile Butadiene Styrene (ABS) material. Systematic control experiments have been carried out with energy, weld time, and hold time variations to investigate their influence on weld properties. The weld test pieces were evaluated using both destructive and non-destructive testing methods to determine their quality and assess the effects of pressure and thermal gradients on the microstructure of the weld. The analysis techniques employed are X-ray diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR), Scanning Electron Microscopy (SEM), Thermogravimetric Analysis (TGA), and Atomic Force Microscopy (AFM). Based on a detailed analysis of the experimental results, the present study offers valuable information concerning the effect of process parameters on the morphology of ABS material battery charger casings. This study showed microstructural and thermal modifications in ABS. Non-optimal parameters may result in localized chain reorientation and nanoscale porosity at the weld interface. The welding procedure preserved the polymer chemistry, but rapid heating and cooling caused localized property alterations, owing to welding-induced phase separation. The conclusions drawn from this research can guide future investigations and advance industrial practices aimed at optimizing the ultrasonic welding process for ABS materials in the context of specific device production.