Ultrasonic spot welding of 5182 aluminum alloy: Evolution of microstructure and mechanical properties

Mohammed, S.M.A.K.; Jiang, Xianquan; Li, D.Y.; Chen, D.L.

doi:10.1016/j.msea.2019.04.059

Cited by 34 publications

(11 citation statements)

References 69 publications

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“…It can be seen that fatigue crack initiated from the outer edge, propagated along the loading direction; as the number of cycles increased, it penetrated through the welding zone towards the inner edge. Mohammed et al [28] also reported that before the applied stress intensity factor reaches the fracture toughness value of the material in the case of lower cyclic loading level, the crack would grow longer, resulting in a fatigue life mostly spent in the stage of crack propagation. Fatigue crack propagation was characterized by the formation of fatigue striations in the crack propagation zone (Figure 4c,f).…”

Section: Resultsmentioning

confidence: 99%

Fracture Characteristics and Analysis in Dissimilar Cu-Al Alloy Joints Formed via Electromagnetic Pulse Welding

et al. 2019

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The aim of this study was to identify and analyze the fatigue fracture characteristics of dissimilar Al 6061 to Cu (UNS C11000) lap joints made with ultrafast electromagnetic pulse welding (EMPW) via fractography, stress analysis and finite element simulation. It was observed that EMPW generated an annular (or ring-shaped) bonding area, with weld zones and a central non-weld zone when viewed from the cross section. Two types of failure modes occurred in relation to the cyclic loading levels: base metal fracture or transverse through-thickness (TTT) crack growth at a higher loading level, and joint interfacial failure at a lower loading level. In the interfacial failure, fatigue crack initiated from the outer edge of annular welding area, and propagated to form an approximate elliptical boundary. Fatigue crack propagation was characterized by fatigue striations existing in discrete areas on the fracture surface. This was attributed to a coupled role of shear and normal stresses present in a tensile lap shear sample due to the bending moment caused by the inherent misalignment. The final rapid fracture started from elliptical boundary with elongated shear dimples. Both theoretical stress analysis and finite element model revealed the maximum stress and stress concentration along the outer edge, where fatigue crack initiation occurred.

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Section: Resultsmentioning

confidence: 99%

Fracture Characteristics and Analysis in Dissimilar Cu-Al Alloy Joints Formed via Electromagnetic Pulse Welding

et al. 2019

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“…The welding energies of as low as 500 J to a maximum of 6000 J were applied in the present study. The sample preparation and welding process could be found elsewhere [14], [15]. A small groove was machined on the faying surface of 20mm15mm to accommodate the K-type thermocouple (diameter = 0.076 mm) for temperature measurements.…”

Section: Methodsmentioning

confidence: 99%

“…where Ft is the peak tensile load, d is the nugget diameter, and t is the sheet thickness. The parameters used in the calculation were detailed in [14], [15].…”

Section: Tensile Propertiesmentioning

confidence: 99%

Ultrasonic Spot Welding Of Aluminum Alloys With And Without Alclad Layer

Mohammed¹,

Albedah²,

Jiang³

et al. 2021

Progress in Canadian Mechanical Engineering. Volume 4

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Solid-state ultrasonic spot welding (USW) of AA5182-AA5182 and Alclad AA7075-AA7075 was performed to evaluate the microstructural features at weld interface, joint robustness and the static and fatigue properties. Strong and defect-free joints were attained in both aluminum alloys via USW. High temperatures at the weld interface were rapidly reached especially at high welding energy levels, which facilitated the weldability of joints. The microstructure of the weld interface evaluated via electron backscatter diffraction (EBSD) exhibited a necklace-like characteristic with fine grains, manifesting the attainment of robust bonding. The obtained tensile lap shear failure load increased with increasing welding energy, with a maximum of ~6 kN satisfied the requirement of AWS D17.2 standards. Furthermore, the welded joints of both alloys exhibited a superior fatigue resistance, with the so-called "unweldable" AA7075 having a fatigue life even somewhat longer than that of AA5182, which was associated with the existence of softer AA7072 Alclad layer. The results obtained in this study demonstrated that USW is a promising solid-state welding technique with shorter weld cycles and high energy-efficiency, which can be used for joining thin sheets in the automotive applications.

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“…In order to visualise the texture formation in the recrystallized regions of good-weld and overweld, the EBSD mapping was performed and shown in Fig. 18 Grain boundary fraction of low angle (LAGB) and high angle (HAGB) grain boundaries [39] in all the weld categories (i.e. under-weld, good-weld and over-weld) were calculated from the EBSD map of Al-Cu interfaces (Fig.…”

Section: Grain Formation Studymentioning

confidence: 99%

Impact of ultrasonic welding on multi-layered Al–Cu joint for electric vehicle battery applications: A layer-wise microstructural analysis

Dhara

Das

2020

Materials Science and Engineering: A

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Ultrasonic spot welding of 5182 aluminum alloy: Evolution of microstructure and mechanical properties

Cited by 34 publications

References 69 publications

Fracture Characteristics and Analysis in Dissimilar Cu-Al Alloy Joints Formed via Electromagnetic Pulse Welding

Fracture Characteristics and Analysis in Dissimilar Cu-Al Alloy Joints Formed via Electromagnetic Pulse Welding

Ultrasonic Spot Welding Of Aluminum Alloys With And Without Alclad Layer

Impact of ultrasonic welding on multi-layered Al–Cu joint for electric vehicle battery applications: A layer-wise microstructural analysis

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