An Analysis of Mechanical Properties for Ultrasonically Welded Multiple C1220-Al1050 Layers

Abstract

This study analyzed the characteristics of aluminum and copper sheets under multi-layer ultrasonic welding, and observed the strength, fracture type, and interface of the weld zone according to location. In addition, an experimental plan was developed using the Taguchi method to optimize the quadruple lap ultrasonic welding process conditions of 0.4t aluminum and copper sheets, and the experiment was performed for each of 25 welding condition. For strength evaluation, the ultrasonic welding performance was evaluated by measuring the tensile strength as a composite material and the shear force at the weld interface through two types of tensile tests: simultaneous tensile and individual tensile. To identify the individual shear strengths of the multi-layer dissimilar ultrasonic welds, three types of tensile tests were performed for each specimen depending on the location of the welded, and as the distance from the horn increased, each of shear strength decreased while the difference in strength value increased. For quadruple lap welding of pure aluminum and copper sheets, the S/N (Signal to Noise Ratio) was the highest at 64.48 with a coarse-grain pattern and optimal welding conditions, and this was selected as the optimal condition. To evaluate the optimized welding condition, additional tests were conducted using the welding conditions that showed the maximum strength values and the welding conditions optimized using the Taguchi method through simple tests. A strength evaluation of the optimized weldment was performed, and for a simultaneous tensile test, it was found that the strength of the optimized weldment was improved by 45% compared to other cases.

Friction Stir Spot Welding of Aluminum and Copper: A Review

“…Solid-state welding processes (FSW, FSSW, USW, EMPW, etc.) have been widely applied to retard the growth of brittle IMCs on the interfaces of dissimilar metals [13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28][29][30][31][32]. As a solid-state welding process, friction stir welding (FSW, invented by TWI, 1991 [13][14][15][16]) can avoid the aforementioned problems in Al-Cu fusion welding joints to a considerable degree due to its low welding temperature and the fierce stirring effect during dynamic welding process.…”