Joining of Various Kinds of Metal Plates Using Ultrasonic Vibrations

Nanaumi, Genki; Mizushima, Daisuke; Ohtake, Naoto

doi:10.1016/j.proeng.2014.10.294

Cited by 8 publications

(3 citation statements)

References 4 publications

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“…Utilizing the same apparatus as Mizushima, Nanaumi et al joined aluminum blanks with a magnesium alloy, copper, titanium, stainless steel, zinc-coated steel, high-strength steel, and clad metal with ultrasonic assistance. 13,14 Energy-dispersive X-ray spectroscopy analyses confirmed the formation of a metallic bonded interface. Wakui and Ohtake used the ultrasonic-assisted clinching for the joining of an aluminum alloy with a carbon fiber-reinforced thermoplastic.…”

Section: Introductionmentioning

confidence: 90%

A novel ultrasonic-assisted staking process for mechanical fasteners

Jäckisch

Merklein

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Increasing material variety in car body engineering causes new challenges regarding the joining processes and therefore, leads to an enhanced usage of mechanical joining technologies. Mechanical fasteners, as self-piercing nuts, can be staked cost-efficiently without a pre-punching operation to create detachable joints. Nevertheless, elevated workpiece strengths lead to high forming forces and a limited application range. One promising approach to reduce tool and workpiece loads in forming operations is superimposing a high-frequency oscillation to the tool movement. The so-called ultrasonic assistance enables an immediate and considerable reduction of the material's flow stress. This beneficial softening effect has been confirmed for several materials and processes. Since the process management and monitoring are highly affected by the frequency-dependent dynamic behavior of the whole test setup, the application of ultrasonic assistance is already challenging for basic forming operations. Hence, only a few studies have been investigating ultrasonic-assisted joining processes. In particular, joining processes with auxiliary elements have been hardly considered. Within the scope of this work, a novel ultrasonic-assisted staking process for mechanical fasteners is proposed. Therefore, the punch movement for the installation of a self-piercing nut into an aluminum sheet is superimposed with a 20 kHz oscillation of 10 µm, 15 µm, and 20 µm amplitude. Ultrasonic assistance in the initial staking phase, characterized by moderate loads, causes irregular tool–specimen contact. Since the effect is promoted by increasing amplitudes, a correlation with the elastic tool deflection is presumed. Additionally, the transferability of the ultrasonic-based force reduction to mechanical joining with auxiliary element is confirmed and a beneficial influence on the joint formation is identified. Thus, ultrasonic assistance is proven as a promising approach for the extension of existing process limits.

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Section: Introductionmentioning

confidence: 90%

A novel ultrasonic-assisted staking process for mechanical fasteners

Jäckisch

Merklein

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…Moreover, the integration of the ultrasonic system into C-framed pliers as well as the formation of sound joints with strengths comparable to conventional formed joints demonstrate the feasibility for industrial use cases. Further investigations in the context of ultrasonic-assisted clinching were carried out in [53] and [57]. In contrast to aforementioned studies, the superimposed oscillation caused a metallic bonding between the joining partners.…”

Section: Ultrasonic-assisted Joiningmentioning

confidence: 99%

Mechanical joining of high-strength multi-material systems − trends and innovations

Merklein

Jäckisch

Kuball

et al. 2023

Mechanics & Industry

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In conjunction with mechanical joining processes. Mechanical joining processes play a key role for the realization of multi-material lightweight structures, which are essential with regard to environmental protection. However, joining of dissimilar high-strength materials is challenging due to the varying properties of the joining partners and due to their high flow stresses and often limited ductility. Thus, the evolution of established processes as well as the development of innovative and highly productive joining technologies are necessary. Requirements for a highly volatile production environment are versatility, flexibility, resilience and robustness. Within this contribution, current trends and innovations related to selected mechanical joining processes for enabling the material mix are outlined in order to point out opportunities to address these requirements in the future. In this context, joining using cold formed pin structures is presented as a promising approach for connecting dissimilar materials like metals to fibre-reinforced plastics. Furthermore, it is shown how the shear-clinching technology can be combined with a process-adapted application of locally limited heat treatment in order to promote the joinability and control the material flow during joining. A novel approach for reducing process forces and expanding process windows is the use of ultrasonic assistance for mechanical joining operations, which is demonstrated by the example of a nut staking process with superimposed high frequency oscillation. As concerns the widely used self-piercing riveting technique, current research activities relate not only to the further development of the joining process itself, for example by combining self-piercing riveting and tumbling, but also to the use of new rivet materials like high strain hardening stainless steels. In addition, the evolution towards mechanical joining 4.0 against the background of data-based process control in conjunction with of mechanical joining processes is also subject of the considerations.

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“…This method is operationally similar to the resistance spot welding used, for instance, in automotive applications. Nanaumi et al (2014) successfully joined dissimilar metal plates, such as copper, titanium and steel, to an aluminium plate using the perpendicular ultrasonic joining method. However, the joining mechanisms for a steel plate with an aluminium alloy plate have not been elucidated.…”

Section: Introductionmentioning

confidence: 99%

Perpendicular ultrasonic joining of steel to aluminium alloy plates

Muñoz-Guijosa

Nanaumi

Ohtani

et al. 2017

Journal of Materials Processing Technology

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Standard and high strength steel plates were successfully joined to A2017 and A6061 aluminium plates by applying ultrasonic power perpendicular to the joint interface instead of tangentially, as in other ultrasonic joining methods Using a 2.9 mm diameter tip, cross tensile strengths of 281 N and 460 N were obtained when joining 0.5 mm thick A6061 plates to 0.5 mm thick commercial and high steel plates, respectively. When joining 0.5 mm thick A2017 plates, the cross tensile strengths were 343 N and 437 N, respectively. Temperature measured at less than 1mm from the joining interface did not exceed 135 • C in any case. The joining mechanisms and resulting joint characteristics are investigated and discussed, alongside parameters affecting the resulting joint performance. Under optimal joining conditions, the cross tensile tests and cross section observations revealed that material fracture resulted in plug failure. No intermetallic layer has been detected with SEM analysis. The joint strengths obtained under those conditions were the maximum attainable for the tip diameter used, provided that they correspond to the stress intensities required to propagate cracks in the aluminium. These results support the conclusion that this ultrasonic joining method, being operationally similar to the method used in resistance spot welding, and providing good performance joints, could be used successfully for high throughput indus-trial applications taking advantage of the available spot welding tooling and operational procedures, as tangential movement of the whole plate is not required.

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Joining of Various Kinds of Metal Plates Using Ultrasonic Vibrations

Cited by 8 publications

References 4 publications

A novel ultrasonic-assisted staking process for mechanical fasteners

A novel ultrasonic-assisted staking process for mechanical fasteners

Mechanical joining of high-strength multi-material systems − trends and innovations

Perpendicular ultrasonic joining of steel to aluminium alloy plates

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