Project Launch “EQUAL”: Artificial Intelligence for Process Monitoring in Ultrasonic Metal Welding

On July 1, 2025, the research project “EQUAL - Single Wire Strand Quantification for the Analysis of Ultrasonic Welded Connections of Stranded Wires” was launched at the Group of Composites and Material Compounds at Chemnitz University of Technology. The project is funded within the framework of the Just Transition Fund (JTF) through the “InfraProNet 2021-2027” program and is co-financed by the European Union and the Free State of Saxony.

The aim of the project is to develop a digital toolbox for process monitoring and defect analysis in ultrasonic metal welding (USMW). This resource-efficient joining process is particularly used in the fields of electromobility, hydrogen technology, and energy supply. It enables the metallurgical bonding of electrical connections, such as between fine stranded wires and terminals, without the use of filler materials or shielding gases. Until now, there has been a lack of practical strategies for systematically evaluating failed welds, which hinders effective process optimization. EQUAL addresses this gap: by using artificial intelligence, the project aims to enable automated detection and analysis of welded joint structures in metallographic cross-section images. A central role is played by the quantification of individual wire strands, i.e., the geometric evaluation and deformation analysis of each individual wire within the weld zone.

In close collaboration with regional and international wire harness manufacturers, both defect-free and intentionally defective welds are produced and systematically analyzed. The findings will be incorporated into a digital toolbox designed to provide operators with intuitive error diagnostics and easy process control, even without in-depth materials expertise. The project not only contributes to quality assurance and process stability but also promotes technology transfer between science and industry in the Chemnitz region. By combining AI-supported analysis with industrial validation, EQUAL makes a significant contribution to sustainable production, structural change in coal regions, and the strengthening of Saxony as a location for science and innovation.

We would like to thank the Just Transition Fund, the European Union, and the Free State of Saxony for supporting this project.