Ultrasonic metal welding of AA 6022‐T4 lap joints: Part I – Technological characterisation and static mechanical behaviour

Annoni, Massimiliano; Carboni, M.

doi:10.1179/1362171810y.0000000014

Cited by 64 publications

(47 citation statements)

References 10 publications

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“…The critical stress intensity ( K c ) in Figure 4c, which is used to better normalize the effect of the energy input, is calculated based on Zhang’s solution [43,58],

K_{c} = 0.694 \frac{F_{t}}{d \sqrt{t}}

where F t is the peak tensile load, t is the sheet thickness and d is the nugget diameter. In the present study, the nugget zone area A = 8 × 5 mm 2 is used to calculate shear strength and the equivalent nugget diameter d is calculated from,

d = \sqrt{\frac{4 A}{π}}

…”

Section: Resultsmentioning

confidence: 99%

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Chen

Jiang

2017

Materials

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The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique–ultrasonic spot welding (USW)–at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with “river-flow” patterns and characteristic fatigue striations.

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“…The critical stress intensity ( K c ) in Figure 4c, which is used to better normalize the effect of the energy input, is calculated based on Zhang’s solution [43,58],

K_{c} = 0.694 \frac{F_{t}}{d \sqrt{t}}

d = \sqrt{\frac{4 A}{π}}

…”

Section: Resultsmentioning

confidence: 99%

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Chen

Jiang

2017

Materials

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“…Vibration energy is applied through a bonding tool attached to the tip of a sonotrode, and this vibration induces relative motion between the bonding materials. A number of studies in the literature have focused on the influence of process parameters, including normal force, vibration amplitude and bonding time, on the bondability of various types of metal sheets [2][3][4][5][6][7][8]. In the ultrasonic bonding process, micro-bonds are initially formed at the bonding interface owing to the relative motion of the bonding material.…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic Bonding of Multi-Layered Foil Using a Cylindrical Surface Tool

Arimoto

Sasaki

Doi

et al. 2019

Metals

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A cylindrical tool was applied for ultrasonic bonding of multi-layered copper foil and a copper sheet to prevent damage to the foil during bonding. The strength of the joints bonded with the cylindrical tool was comparable to that of the joints bonded with a conventional knurled tool. The effect of the cylindrical surface tool on bondability was investigated thorough relative motion behaviors between the tool surface and the bonding materials, as well as on bond microstructure evolution. The relative motion was visualized with in-situ observation using a high-speed camera and digital image correlation. At shorter bonding times, relative motions occurred at the bonding interfaces of the foil and the copper sheet. Thereafter, the relative motion between the tool and the bonding material became predominant owing to bond formation at the bonding interface, resulting in a macroscopic plastic flow in the bonded region. This relative motion damaged the foil in knurled tool bonding, and the cylindrical tool achieved bonding without any damage.

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“…In the meantime, specific considerations are taken to the repetition of experiments as it decreases the variability in experimental results and expands their significance and liableness. This is one of the scientific techniques which help to boost the confidence level of a welder to reach conclusions about an experimental variable [22]. So, using this design, the number of experimental runs was 45 with six replicates for each test condition.…”

Section: Experimentation and Data Collectionmentioning

confidence: 99%

Modeling and optimization of ultrasonic metal welding on dissimilar sheets using fuzzy based genetic algorithm approach

Satpathy

Moharana

Dewangan

et al. 2015

Engineering Science and Technology, an International Journal

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a b s t r a c tUltrasonic welding has been used in the market over the past twenty years and serving to the manufacturing industries like aviation, medical, microelectronics and many more due to various hurdles faced by conventional fusion welding process. It takes very short time (less than one second) to weld materials, thus it can be used for mass production. But many times, the problems faced by industries due to this process are the poor weld quality and strength of the joints. In fact, the quality and success of the welding depend upon its control parameters. In this present study, the control parameters like vibration amplitude, weld pressure and weld time are considered for the welding of dissimilar metals like aluminum (AA1100) and brass (UNS C27000) sheet of 0.3 mm thickness. Experiments are conducted according to the full factorial design with four replications to obtain the responses like tensile shear stress, T-peel stress and weld area. All these data are utilized to develop a non-linear second order regression model between the responses and predictors. As the quality is an important issue in these manufacturing industries, the optimal combinations of these process parameters are found out by using fuzzy logic approach and genetic algorithm (GA) approach. During experiments, the temperature measurement of the weld zone has also been performed to study its effect on different quality characteristics. From the confirmatory test, it has been observed that, the fuzzy logic yields better output results than GA. A variety of weld quality levels, such as "under weld", "good weld" and "over weld" have also been defined by performing micro structural analysis.

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Ultrasonic metal welding of AA 6022‐T4 lap joints: Part I – Technological characterisation and static mechanical behaviour

Cited by 64 publications

References 10 publications

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Ultrasonic Bonding of Multi-Layered Foil Using a Cylindrical Surface Tool

Modeling and optimization of ultrasonic metal welding on dissimilar sheets using fuzzy based genetic algorithm approach

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