Effects of Vibration Amplitude on Microstructure Evolution and Mechanical Strength of Ultrasonic Spot Welded Cu/Al Joints

Liu, Jian; Biao, Cao; Yang, Jingwei

doi:10.3390/met7110471

Cited by 17 publications

(10 citation statements)

References 26 publications

(51 reference statements)

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“…The range of strengths that is achieved for this welding time is larger than for the other welding times, proving that when welding times are too high, it becomes more difficult to realize a joint with maximal weld strength. This is in agreement with the observations of Liu et al, where the tensile strength of Cu-Al joints first increased and then decreased again with welding time at a constant amplitude, showing that there is an optimal welding time where a maximal weld strength is achieved [32].…”

Section: Influence Of the Welding Parameters On The Tensile Strengthsupporting

confidence: 93%

Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding

Silva

Meester

Faes

et al. 2022

JMMP

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The demand for joining dissimilar metals has exponentially increased due to the global concerns about climate change, especially for electric vehicles in the automotive industry. Ultrasonic welding (USW) surges as a very promising technique to join dissimilar metals, providing strength and electric conductivity, in addition to avoid metallurgical defects, such as the formation of intermetallic compounds, brittle phases and porosities. However, USW is a very sensitive process, which depends on many parameters. This work evaluates the impact of the process parameters on the quality of ultrasonic spot welds between copper and aluminium plates. The weld quality is assessed based on the tensile strength of the joints and metallographic examination of the weld cross-sections. Furthermore, the welding energy is examined for the different welding conditions. This is done to evaluate the influence of each parameter on the heat input resulting from friction at the weld interface and on the weld quality. From the obtained results, it was possible to optimise parameters to achieve satisfactory weld quality in 1.0 mm thick Al–Cu plate joints in terms of mechanical and metallurgical properties.

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Section: Influence Of the Welding Parameters On The Tensile Strengthsupporting

confidence: 93%

Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding

Silva

Meester

Faes

et al. 2022

JMMP

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“…The formation of a joint in ultrasonic welding involves a large number of influencing factors and their interactions. Macroscale testing of the joint load-bearing capacity and microscopic observations of the joint from previous researches for similar [37] and dissimilar [16,26,65] material pairs point to the fact that process parameters are the crucial factors in the origin of the local bonds. Therefore, two factors, namely sliding velocity and compression rate, have been chosen and their influences on the joint formation and diffusion of Al atoms at the atomic scale have been studied.…”

Section: Resultsmentioning

confidence: 92%

Molecular dynamics simulation of interface atomic diffusion in ultrasonic metal welding

Mostafavi

Bamer

Markert

2021

Int J Adv Manuf Technol

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The formation of a reliable joint between a large number of aluminum strands for battery applications is crucial in automotive industry, especially in the technology of autonomous vehicles. Therefore, in this study, mechanical deformations and diffusion patterns of the mating interface in ultrasonic welding of aluminum were investigated using molecular dynamics simulations. Furthermore, microscopic observations of the joints between aluminum strands from ultrasonic welding illustrating the influence of two process parameters were done. To study the nanomechanics of the joint formation, two aluminum crystallites of different orientations were built. The impact of the sliding velocity and the compression rate of the upper crystal block on the diffusion pattern at the interface of the two crystallites were quantified via the diffusion coefficient. Tensile deformations of several joint configurations were performed to investigate the load-bearing capacity of the solid state bond, taking into account the compression rate, the sliding velocity and the crystallite orientation. The atomic scale simulations revealed that the orientations of the crystallites govern the interface diffusion and the tensile strength of the joint significantly. Furthermore, interface atom diffusion increased with increasing the sliding velocity. Additionally, it was observed that a higher sliding velocity enhances the friction heat generation between the crystallites and significantly increases the interface temperature.

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“…However, the application of HP-USW results in the need of increased higher clamping forces to keep the weldments together. Liu et al [23], who studied the vibration amplitude effects on ultrasonic welding of Cu-Al joints, also noticed that interactions between different USW parameters have great influence on the mechanical performance of the joints, however a moderate clamping force is indispensable in generating intimate contact between the welded samples, and high power levels are required for extensive deformation that is associated with high clamping force.…”

Section: Lap Shear Tensile Test Resultsmentioning

confidence: 99%

Interface Characterization of Ultrasonic Spot-Welded Mg Alloy Interlayered with Cu Coating

Badamian

Iwamoto

Sato

et al. 2019

Metals

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The effect of Cu coating metallic interlayer on the weldability, joint strength, and interfacial microstructure during high-power ultrasonic spot welding (HP-USW) of AZ31B Mg alloy has been studied. Interlayered samples exhibited good weldability and they resulted in strong sound joints with nearly the same strength as joints without interlayer, with the distinction of lower energy being required. The Cu interlayer affected the thermal and vibrational properties of the interface, as the maximum interface temperature decreased and approached better uniformity across the weld nugget. The base metal grain structure changed to equiaxed larger grains after ultrasonic welding and a chain of parent metal small grains were observed around the interface. A binary intermetallic compound product of Mg-Cu, which was rich in Mg, has been found around the interface that was diffused toward base metal. According to the electron probe micro-analyzer (EPMA) results, alongside temperature measurements and hardness data, the formation of Mg2Cu is suggested in this region. At the interface centerline, a narrow region was identified that was composed of Mg, Cu, and Al. Complementary transmission electron microscopy analysis estimated that Al-containing reaction product is a ternary alloy of the MgCuxAly type. The dispersion of fine grain intermetallic compounds as discrete particles inside Mg substrate in both interfacial regions formed a composite like structure that could participate in joint strengthening.

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Effects of Vibration Amplitude on Microstructure Evolution and Mechanical Strength of Ultrasonic Spot Welded Cu/Al Joints

Cited by 17 publications

References 26 publications

Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding

Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding

Molecular dynamics simulation of interface atomic diffusion in ultrasonic metal welding

Interface Characterization of Ultrasonic Spot-Welded Mg Alloy Interlayered with Cu Coating

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