Dissimilar ultrasonic spot welding of rare-earth containing ZEK100 magnesium-to-aluminum alloy with a zinc interlayer: Microstructural evolution and mechanical properties

He, Peng; Chen, D.L.; Guo, Shuyu; Hong, H.; Zheng, Kailun; Bai, Xuefei; Li, D.Y.; Jiang, Xian Quan

doi:10.1016/j.jmapro.2023.03.014

Cited by 12 publications

(2 citation statements)

References 57 publications

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“…However, at 200 J welding energy, grain refinement did not significantly improve the strength of the joints. Although the interfacial grain size could be refined by plastic deformation, 20 the higher porosity still limited the increase in strength.…”

Section: Resultsmentioning

confidence: 99%

Ultrasonic welding of Cu cables bonding: Tensile, porosity and evolution of microstructure

Cheng,

Yang,

et al. 2024

Science and Technology of Welding and Joining

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Tensile strength, porosity and microstructure evolution of ultrasonic bonding for BVR2.5 Cu cables at different welding energies were investigated. By X-ray computed tomography and modification of the Johnson-Cook model, the predictive model of porosity was developed for the first time to assess joint strength. When the porosity was lower than 19%, the joint formed a good bond and reached the tensile strength of 585.7 ± 17.9 N. The maximum joint tensile strength was achieved at about 10% porosity. The Cu grains at the interface underwent plastic deformation, discontinuous dynamic recrystallisation and dynamic recovery to form a good bond. Interfacial grains are refined by ultrasonic vibrations, but the reduction of the porosity is the critical factor in improving joint strength.

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Section: Resultsmentioning

confidence: 99%

Ultrasonic welding of Cu cables bonding: Tensile, porosity and evolution of microstructure

Cheng,

Yang,

et al. 2024

Science and Technology of Welding and Joining

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“…Joining dissimilar materials is often challenging due to the differences in chemical, mechanical, thermal, or electrical properties. As a low-cost and environment-friendly technique, ultrasonic welding is extensively used to join dissimilar materials, such as aluminum/steel [3][4][5], aluminum/magnesium [6,7], aluminum/titanium [8], and metal/fiber-reinforced polymers [9] in automotive, aviation, and aerospace applications. As ultrasonic welding provides advantages in joining multiple thin sheets of highly conductive materials, it serves as one of the major joining techniques in current automotive lithium-ion-based battery manufacturing [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools

Li,

Rienks,

Balle

2023

Metals

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In current automotive lithium-ion battery manufacturing, Ultrasonic Metal Welding (USMW) is one of the major joining techniques due to its advantages in welding multiple thin sheets of highly conductive materials. The sonotrode, serving as the welding tool, transmits high-frequency oscillation to the joining parts. Due to the high frequency of thermal-mechanical loading, the knurl pattern on the sonotrode wears with an increasing number of welds, which significantly influences the welding process, resulting in poor joint quality. In this study, a high-frequency test system was developed to investigate the wear mechanisms of the sonotrode. Based on the comparable relative motion to the welding process, the thermal-mechanical loadings on the contact area were analyzed. As the oscillation amplitude of the sonotrode increased, the estimated frictional force between the sonotrode and the copper counter body remained constant, while an increase in the sliding distance was observed in the contact area. Temperature development showed a strong correlation with mechanical loading. A first approach of continuous testing was performed but was limited due to the failure of the copper counter body under ultrasonic stimulation.

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Dissimilar ultrasonic spot welding of ZEK100 magnesium alloy to a clad AA7075 aluminum alloy: Tensile and fatigue properties

Dash,

Kesharwani,

Albedah

et al. 2023

Int J Adv Manuf Technol

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Dissimilar ultrasonic spot welding of rare-earth containing ZEK100 magnesium-to-aluminum alloy with a zinc interlayer: Microstructural evolution and mechanical properties

Cited by 12 publications

References 57 publications

Ultrasonic welding of Cu cables bonding: Tensile, porosity and evolution of microstructure

Ultrasonic welding of Cu cables bonding: Tensile, porosity and evolution of microstructure

Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools

Dissimilar ultrasonic spot welding of ZEK100 magnesium alloy to a clad AA7075 aluminum alloy: Tensile and fatigue properties

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