Weld joint characterization in ultrasonic welding of phosphor bronze sheets

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

doi:10.1016/j.jestch.2021.07.003

Cited by 5 publications

(2 citation statements)

References 29 publications

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“…It also exhibits good thermal and electrical conductivity, making it useful in heat exchangers and electrical connectors. Prosper Bronze's diverse range of properties makes it a favoured choice across industries for applications requiring strength, corrosion resistance, wear resistance, machinability, and aesthetic appeal [2].…”

Section: Introductionmentioning

confidence: 99%

Mechanical and Corrosion Properties of Friction Stir Welded and Tungsten Inert Gas Welded Phosphor Bronze

Gopi,

Mohan,

Natarajan

2023

Advances in Materials Science

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This study investigated the mechanical and corrosion properties of Friction Stir Welded (FSW) and Tungsten Inert Gas (TIG) welded phosphor bronze (CuSn4) joints. Corrosion tests were conducted on the welded joints, and the percentage of weight loss due to corrosion was measured at different time intervals. Results revealed that the percentage of weight loss due to corrosion of the TIG joint increased with time, whereas the percentage of weight loss due to corrosion of the FSW welded joint remained constant. This could be attributed to recrystallisation that happened in the solid-state welding, which reduced corrosion in the FSW welded joint. In addition, tensile tests were conducted to evaluate the strength of the joints. FSW with a spindle speed of 1300 rpm, weld speed of 0.06mm/sec, plunge depth of 0.25mm, pin profile of pentagon, and flat shoulder profile was found to produce good results. TIG welding with a welding speed of 1.75mm/sec, a gas flow rate of 7.5 cm3/min and an amperage of 120A also produced good results. The tensile strength of FSW was found to be approximately 1.6 times higher than that of TIG welding.

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Section: Introductionmentioning

confidence: 99%

Mechanical and Corrosion Properties of Friction Stir Welded and Tungsten Inert Gas Welded Phosphor Bronze

Gopi,

Mohan,

Natarajan

2023

Advances in Materials Science

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“…However, the lack of understanding of the welding behavior of each layer in the multilayer stack structure hinders the large-scale production in the manufacture of electric vehicle batteries. Although the current research on USW is very active, most focus on the mechanics and mechanism between bilayer similar or dissimilar metals [21][22][23][24][25]. Such as the research of Bakavos and Prangnell [21] reported interface to curl, vortex, ripple, and microbonding are the mechanisms behind the weld.…”

Section: Introductionmentioning

confidence: 99%

Study on the bonding mechanism of multilayer copper with nickel sheet in ultrasonic welding process

Ye¹,

Wang²,

Lu³

et al. 2022

Mater. Res. Express

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The metal-plastic flow and bonding strength of three-layer copper (Cu) with single-layer nickel (Ni) joints via ultrasonic welding were investigated in this study. With the increase of welding time from 0.3 to 0.5 s, the weld bonding density between different layers’ interface increased gradually and approached about 95±1.5%. Electron backscatter diffraction (EBSD) analysis of different regions of the welded joint revealed that the metal grains in the 1st layer became relatively small and elongated, while the 2nd and 3rd layers tended to be equiaxed grains. The joint bonding strength of T-peel tests changed with welding time and had two kinds of fracture models (nugget pullout and interfacial fracture). Compared with the bonding strength of the 1st-2nd and 3rd-4th interface, the 2nd-3rd interface of joints had the highest bonding strength of 400.6 N with nugget pullout fracture model at welding time of 0.4 s. In addition, the much higher hardness of the 1st layer is attributed to the strong plastic deformation of the 1st layer, while the dynamic recovery and dynamic recrystallization of the metal of the 2nd layer resulted in the decrease of hardness.

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A technical perspective on integrating artificial intelligence to solid-state welding

Yaknesh,

Rajamurugu,

Babu

et al. 2024

Int J Adv Manuf Technol

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The implementation of artificial intelligence (AI) techniques in industrial applications, especially solid-state welding (SSW), has transformed modeling, optimization, forecasting, and controlling sophisticated systems. SSW is a better method for joining due to the least melting of material thus maintaining Nugget region integrity. This study investigates thoroughly how AI-based predictions have impacted SSW by looking at methods like Artificial Neural Networks (ANN), Fuzzy Logic (FL), Machine Learning (ML), Meta-Heuristic Algorithms, and Hybrid Methods (HM) as applied to Friction Stir Welding (FSW), Ultrasonic Welding (UW), and Diffusion Bonding (DB). Studies on Diffusion Bonding reveal that ANN and Generic Algorithms can predict outcomes with an accuracy range of 85 – 99%, while Response Surface Methodology such as Optimization Strategy can achieve up to 95 percent confidence levels in improving bonding strength and optimizing process parameters. Using ANNs for FSW gives an average percentage error of about 95%, but using metaheuristics refined it at an incrementally improved accuracy rate of about 2%. In UW, ANN, Hybrid ANN, and ML models predict output parameters with accuracy levels ranging from 85 to 96%. Integrating AI techniques with optimization algorithms, for instance, GA and Particle Swarm Optimization (PSO) significantly improves accuracy, enhancing parameter prediction and optimizing UW processes. ANN’s high accuracy of nearly 95% compared to other techniques like FL and ML in predicting welding parameters. HM exhibits superior precision, showcasing their potential to enhance weld quality, minimize trial welds, and reduce costs and time. Various emerging hybrid methods offer better prediction accuracy.

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Weld joint characterization in ultrasonic welding of phosphor bronze sheets

Cited by 5 publications

References 29 publications

Mechanical and Corrosion Properties of Friction Stir Welded and Tungsten Inert Gas Welded Phosphor Bronze

Mechanical and Corrosion Properties of Friction Stir Welded and Tungsten Inert Gas Welded Phosphor Bronze

Study on the bonding mechanism of multilayer copper with nickel sheet in ultrasonic welding process

A technical perspective on integrating artificial intelligence to solid-state welding

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