Microstructural characterization and mechanical properties of high power ultrasonic spot welded aluminum alloy AA6111–TiAl6V4 dissimilar joints

Zhang, Chaoqun; Robson, James; Ciuca, Octav; Prangnell, P.B.

doi:10.1016/j.matchar.2014.09.001

Cited by 77 publications

(23 citation statements)

References 24 publications

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“…Ultrasonic welding (USW) in metals is a solid-state joining process for making lap welds, in which high-frequency vibrations are applied parallel to the weld interface under a static clamping pressure. As a solid state joining method, USW avoids many of the undesirable phenomena observed in fusion welding of metals, such as solidification cracking, grain boundary liquation cracking, porosity and micro-segregation, while enabling the control of the formation of brittle intermetallic phases in dissimilar metal welding [1][2][3][4]. The process has become applicable to sheet metal up to a few mm thick, thanks to the availability of higher power welding systems.…”

Section: Introductionmentioning

confidence: 99%

“…Prangnell et al [2] successfully joined Al 6111 and DC04 steel, with all of the deformation occurring in the Al sheet, but with lower joint strength than in Al-Al welds due to the growth of an intermetallic reaction layer. Dissimilar Al-Ti ultrasonic welds however gave comparable strength to Al-Al welds, which was attributed to the lack of formation of brittle intermetallics (Zhang et al [4,6]). Attempts to ultrasonically weld Al 6111 to Mg AZ31 reported by Panteli et al [3] and Robson et al [7] were less successful than Mg-Mg USW, with poor fracture behaviour due to the rapid development of a thick IMC layer at the joint interface, and eutectic melting at the interface for welding times over 1s.…”

Section: Introductionmentioning

confidence: 99%

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Finite element analysis of heat generation in dissimilar alloy ultrasonic welding

Jedrasiak

Shercliff

2018

Materials & Design

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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.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Finite element analysis of heat generation in dissimilar alloy ultrasonic welding

Jedrasiak

Shercliff

2018

Materials & Design

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“…After the end of welding process, the heat would dissipate to the sonotrode, the anvil and air. This process was familiar with the annealing process which could soften the material [15].…”

Section: Hardness Profilesmentioning

confidence: 99%

The Effect of Ultrasonic Energy on Joint Characterization in Ultrasonic Spot Welding Multilayer Tabs Used in Lithium-ion Battery Manufacturing

Zhang

2019

MATEC Web Conf.

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Lithium-ion battery for electric vehicles contains a large number of battery tabs with multiple and thin sheets. Dissimilar metals are often used for different electrodes, for example, the copper and nickel are often used for negative electrode and the aluminum is often used for positive electrode. Meanwhile the thickness of metal sheets are various at different locations. Ultrasonic spot welding is very capable of welding similar and dissimilar combinations. However, there are less heat generation and plastic deformation in the bottom interfaces where ultrasonic energy is difficult to reach. This will result in the unbonded region occurrence caused by ultrasonic energy attenuation. In this work, experimental investigation was conducted to identify the effect of ultrasonic energy on joint characterization in ultrasonic welding multiple tabs by comparing the plastic deformation in different layers and various joint interfaces. Two sonotrodes with different knurl size were used to produce the welding energy for the tabs joining. Samples were cross-sectioned along vibration direction to obtain hardness profiles and metallographic maps. The hardness profile can be used to identify the changes of grain morphology. Hardness and grain size changes in different layers were also studied to reflect how ultrasonic energy decrease from top to bottom in battery tabs. Thereby, the relationship between material attributes and ultrasonic energy loss was established based on the experimental results.

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“…Beside this, aluminum alloy has been welded to titanium and copper alloy by ultrasonic vibrations with no intermetallic layer reaction [32,33]. A thin metal wire, applied as electrical connections, was welded into polymer as well by ultrasonic vibrations [19].…”

Section: Development Of Ultrasonic Hot Embossing 21 Ultrasonic Weldimentioning

confidence: 99%

Tools for ultrasonic hot embossing

et al. 2014

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Microstructural characterization and mechanical properties of high power ultrasonic spot welded aluminum alloy AA6111–TiAl6V4 dissimilar joints

Cited by 77 publications

References 24 publications

Finite element analysis of heat generation in dissimilar alloy ultrasonic welding

Finite element analysis of heat generation in dissimilar alloy ultrasonic welding

The Effect of Ultrasonic Energy on Joint Characterization in Ultrasonic Spot Welding Multilayer Tabs Used in Lithium-ion Battery Manufacturing

Tools for ultrasonic hot embossing

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