The effect of horn knurl geometry on battery tab ultrasonic welding quality: 2D finite element simulations

Lee, Dong-Kyun; Cai, Wayne

doi:10.1016/j.jmapro.2017.04.009

Cited by 40 publications

(21 citation statements)

References 16 publications

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“…The literature summarised in Table 1 shows that the prime objectives of all thermomechanical modelling are to predict the temperature history and heat generation as a function of process conditions, and in many cases the evolution of the state and shape of the deformation zone, and development of the full bond -though experimental validation is not always provided. Knowledge of the process conditions is then applied to interpret or predict other aspects of the process -for example: (i) an indication of the joint strength [11] or fracture energy [12,13]; (ii) the effect of the sonotrode knurl pattern on interface deformation and bond formation [21][22][23][24][25]; and (iii) grain size and microhardness in the weld zone [26].…”

Section: Literature Review: Modelling Of Uswmentioning

confidence: 99%

“…But in USW, there are the added complications of kinematic hardening due to the cyclic deformation conditions, plus the phenomenon of ultrasonic softening in which high frequency cyclic oscillation leads to a further reduction in flow stress (sample data are discussed later). Different authors in Table 1 have allowed for different factors by making empirical modifications, with a few implementing responses that aim to capture all of the phenomena in USW [21,25,26]. Constitutive data for many alloys are relatively sparse or incomplete for conventional hot deformation in the temperature and strain-rate regimes of friction processingand even more so in the high frequency cyclic domain of USW.…”

Section: Literature Review: Modelling Of Uswmentioning

confidence: 99%

“…Nonetheless, most of the previous approaches to modelling USW still lack computational efficiency, by attempting to model the 1000s of cycles taken, due to the very high frequency of the process. Several authors comment on this problem, and adapt their implementation to improve computational efficiency -for example, using explicit analysis to predict the frictional heat flux, which then served as an input to an implicit analysis of the entire process [20], and the common techniques of limiting the model size and grading the mesh [22][23][24][25], or simplifying to 2D [21]. Some authors have sought computational efficiency by making simplifications that avoid the challenges of high frequency and thermomechanical coupling completely, while capturing some of the essential mechanical chacateristics.…”

Section: Literature Review: Modelling Of Uswmentioning

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: Literature Review: Modelling Of Uswmentioning

confidence: 99%

Section: Literature Review: Modelling Of Uswmentioning

confidence: 99%

Section: Literature Review: Modelling Of Uswmentioning

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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“…where R st is the resistance of the sonotrode, R Cu is the resistance of Cu plate, R Al is the resistance of Al plate, R av is the resistance of the anvil, R c1 is the contact resistance between the sonotrode and the upper specimen, R c2 is the contact resistance between the upper and the lower specimen, and R c3 is the contact resistance between the anvil and the lower specimen. In RUSW, material softening arises from two sources: Ultrasonic softening and thermal softening [19]. Thus, the material softening rate in the welding process can be expressed as [18]:…”

Section: The Principle Of Hybrid Weldingmentioning

confidence: 99%

Microstructure and Mechanical Properties of Resistance Heat-Assisted High-Power Ultrasonic Dissimilar Welded Cu/Al Joint

Biao

2019

Metals

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The Cu/Al dissimilar joint, welded by high-power ultrasonic welding technology, is still facing challenges despite the significant research attention it has attracted. In this work, the microstructure and mechanical properties of resistance heat-assisted high-power ultrasonic welding of Cu/Al are investigated, in order to obtain high-quality joints. The intermetallic compound (IMC) at the interface of hybrid welding is primarily composed of Al2Cu, and the additional resistance of heat reduces the thickness of this brittle IMC layer. The average shear stress for the joint prepared by hybrid welding is~97 MPa, which is higher compared to the joint strength without resistance heat (90 MPa). Moreover, the duration of the hybrid welding process is shorter. Finally, the fracture of the hybrid weld is found to be a brittle-ductile hybrid mode.

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“…The camera with high capture frequency was set towards the lateral side of four layers of material to capture the displacement of each layer during the welding process. Lee et al [11] created a 2D finite element model to simulate temperature and structure field of a four-sheets structure where sonotrodes with different geometry were used. Also different welding parameter was selected to compare the different results.…”

Section: Introductionmentioning

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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The effect of horn knurl geometry on battery tab ultrasonic welding quality: 2D finite element simulations

Cited by 40 publications

References 16 publications

Finite element analysis of heat generation in dissimilar alloy ultrasonic welding

Finite element analysis of heat generation in dissimilar alloy ultrasonic welding

Microstructure and Mechanical Properties of Resistance Heat-Assisted High-Power Ultrasonic Dissimilar Welded Cu/Al Joint

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

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