Mechanism of joint formation and characteristics of interface in ultrasonic welding: Literature review

Sanga, Bharat; Wattal, Reeta; Nagesh, D. S.

doi:10.21533/pen.v6i1.158

Cited by 13 publications

(13 citation statements)

References 28 publications

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“…Based on the material’s behaviour in a liquid state while fusion welding, proper fluid flow is essential to efficiently weld either metals or alloys. Copper and nickel are the examples that have been welded successfully [ 51 , 52 , 53 , 54 , 55 ] despite vast differences in viscosities (see Figure 3 ). Mutual solubility plays a vital role in obtaining better macro and microstructural bonding, i.e., even after favourable flow conditions of the materials during fusion welding.…”

Section: Introduction—joining Of Copper To Stainless Steel Bimetallic...mentioning

confidence: 99%

The Joining of Copper to Stainless Steel by Solid-State Welding Processes: A Review

et al. 2022

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Joining immiscible materials such as copper and stainless steel together is a significant concern due to distinct mechanical and metallurgical properties across the joint line, such as melting points, the coefficient of linear thermal expansion, and thermal conductivity. The joint properties of copper to stainless steel welds are in great demand for various mechanical components of the international thermonuclear experimental reactor, ultra-high vacuum system, plan wave linear-accelerator or linac structure, and heat exchanger. These dissimilar-metals joints offer excellent flexibility in design and production, leading to a robust structure for many cutting-edge applications. Hence, the present article reviews the copper to stainless steel joining mechanism under different solid-state processing conditions. The present understanding says that defect-free strong joints between the dissimilar metals are systematically possible. Apart from this understanding, the authors have identified and highlighted the gaps in the research exploration to date. Moreover, a sustainable methodology to achieve a desirable weld of copper to stainless steel depends on favorable processing conditions.

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Section: Introduction—joining Of Copper To Stainless Steel Bimetallic...mentioning

confidence: 99%

The Joining of Copper to Stainless Steel by Solid-State Welding Processes: A Review

et al. 2022

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“…Величина сжимающей силы может варьироваться в широких пределах в зависимости от установки, толщины привариваемого листа и его прочности. Повышение температуры в зоне контакта и высокоскоростная знакопеременная сдвиговая деформация приводят к структурным изменениям в свариваемых материалах, которые не только влияют на прочность соединений [8; 9; 18], но и лежат в основе механизма формирования соединения [19]. Время сварки и подводимая мощность определяют энергию сварки, и, как правило, в цитированных выше работах в основном исследовано влияние энергии сварки на прочность соединений, полученных ультразвуковой сваркой.…”

Section: Introductionunclassified

“…Несмотря на значительное количество структурных исследований, физические принципы формирования соединений при УЗС окончательно не установлены. Отмечается возможность образования соединений как за счет механического перемешивания слоев металлов в зоне контакта (обычно при высоких энергиях сварки) [2], так и за счет развития деформационных и диффузионных процессов [19]. Так, например, в работе [17] на основании исследований консолидации алюминиевых сплавов 6061O авторы предположили, что во время сварки крупнозернистых листов из-за теплоты, выделяемой за счет трения и пластической деформации, происходит непрерывная динамическая рекристаллизация.…”

Section: Introductionunclassified

Microstructure and strength of joints of nickel sheets produced by ultrasonic welding

Shayakhmetova¹,

Murzinova²,

Назаров³

2021

Vektor nauki Tol'yattin. gos. univ.

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Ultrasonic welding (USW) is one of the methods for producing solid-phase joints of thin metal sheets, which in the future can be used to obtain laminated composite materials, for additive manufacturing and renovation of metallic articles. The quality of joints depends on both the processing conditions and the properties of welded metals and alloys. At present, the USW conditions, the properties, and structure of weld joints of strong metals, in particular, of nickel, are underexplored. In this work, the authors studied the influence of the compressive load magnitude on the lap shear strength and the structure of joints of annealed nickel sheets with a thickness of 0.5 mm produced by spot USW. The authors carried out USW at a vibration frequency of 20 kHz with an amplitude of 15 μm, the time of welding was equal to 2 s. The compressive load magnitude was varied from 3.5 to 7 kN. The study showed that with an increase in the compressive load in the considered range of values, the strength of weld joints increased, reached a maximum, and then decreased. The joints obtained at the compressive load of 6 kN demonstrated the highest lap shear strength of 1950 N. A zone of thermomechanical influence with a gradient microstructure is observed near the contact of the welded surfaces. In a layer with a thickness of 10–20 mm, the initial coarse-grained structure of nickel is transformed into an ultra-fine-grained one with a grain size of less than 1 mm. The ultra-fine-grained layer neighbors on crystallites, the size of which is several micrometers and increases with a distance from the contact surface of welded sheets. The authors compared the results of mechanical lap shear tests and structural studies with the data obtained after ultrasonic welding of nickel, aluminum, and copper alloys.

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“…Fairly seen simple from outside, the actual mechanism of joint formation in USW is quite complex [8]. In fact, an accurate and well-established theory related to the joint mechanism of USW is yet to be developed [9]. There is a need to regulate the operating procedure to make this technique a commonly utilized popular joining method.…”

Section: Introductionmentioning

confidence: 99%

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

Sanga

Wattal

Nagesh

2021

JMES

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The ultrasonic joining of phosphor bronze sheets is analyzed using a 3-D finite element model for the study and prediction of the thermal profiles at the weld interface. The heat fluxes are calculated and assigned as boundary conditions during the thermal simulation. The forecast of temperature is done under various welding conditions. The maximum temperature obtained by transient simulation at the weld interface is 366.74℃. The continuous reduction in the temperature is observed towards the extremes of the weld metal. The sonotrode and the anvil achieve a lower temperature in comparison to the weld interface. The effect of clamping force and bonding ratio on the interface temperature is observed as positive. The model is validated with an error of 1.576% between the observed and predicted temperature results and a correlation co-efficient 0.96 is established between the simulated temperature results and the weld strength. Sufficiently strong joints were obtained at the optimum welding conditions with 74% joint efficiency. 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.

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Mechanism of joint formation and characteristics of interface in ultrasonic welding: Literature review

Cited by 13 publications

References 28 publications

The Joining of Copper to Stainless Steel by Solid-State Welding Processes: A Review

The Joining of Copper to Stainless Steel by Solid-State Welding Processes: A Review

Microstructure and strength of joints of nickel sheets produced by ultrasonic welding

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

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