Finite element analysis of heat generation in dissimilar alloy ultrasonic welding

Abstract

This paper presents a computationally efficient finite element analysis of the heat generation in ultrasonic welding (USW). The temperature field is predicted from a continuous thermal model, with the heat generation rate being calculated intermittently, using a deformation model for single cycles of oscillation. The model was applied to USW of Al 6111 to itself, and to DC04 steel and Ti6Al4V, with plastic deformation only occurring in the Al alloy. Ultrasonic softening was allowed for empirically in the constitutive plastic response of the Al alloy. The predicted heat generation rate for all three material combinations was consistent with that inferred from thermocouple data and the thermal model. Material deformation maps were developed as a means of illustrating the dominant deformation regime of temperature and strain-rate. The thermal and deformation models were then fully coupled, as a proof of concept, to demonstrate that the power and temperature histories can be predicted directly from the constitutive data for the alloy and a kinematic description of the process.

Heat Source Analysis on Ultrasonic Welding of Plastic Structural Components Based on Numerical Simulation

“…Natesh et al [14] calculated the viscoelastic heat and frictional heat of different characteristic temperature sections in the ultrasonic plastic welding process using the finite element method, analyzed the heat generation mechanism of frictional heat and viscoelastic heat, and verified the numerical simulation results through experiments. The ultrasonic welding that can achieve the welding of long carbon fiber composite materials has three weld modes -time mode, displacement mode and energy mode, with differences in their control mechanisms [15][16][17][18][19]. Huang et al [20] calculated and compared the optimal welding parameters in each mode, plotted a power-displacement curve describing the heat transfer mechanism of the welding process, and verified its accuracy through microstructure observations in the experiments.…”

An FEA based study of thermal behaviour of ultrasonically welded phosphor bronze sheets

“…It is evident that the interface temperature has a strong linear relationship with joint strength and is a major deciding factor for achieving strong joints. journal.ump.edu.my/jmes ◄ welded joints [14][15][16][17][18][19][20][21]. Zhong et al [14] performed an experimental study and modelling of the ultrasonic consolidation process of dissimilar Ti and Al alloys.…”

“…A 3-D finite element model of the thermal field was applied for temperature prediction at the weld interface. The same author also simulated the heat generation in USW using finite element analysis [21]. A single cycle oscillation deformation model was employed for calculating the heat generation rate sporadically.…”

Overview on the Evolution of Laser Welding of Vascular and Nervous Tissues

“…Therefore, important research on welding technology is being conducted. As widely spread conventional fusion welding processes are no longer an effective solution for joining some materials and material combinations, the most explored research issue has been the optimization of nonconventional welding processes, such as friction stir welding [1,2], ultrasonic welding [3,4], diffusion welding [5,6], magnetic pulse welding [7,8], laser welding, etc. Laser welding presents excellent characteristics, specifically, its accuracy and high-power density, enabling the production of very localized welds, with minimal distortion and with a residual heat-affected zone.…”