Modeling of high-power ultrasonic welding of Cu/Al joint

Li, Huan; Biao, Cao; Liu, Jian; Yang, Jingwei

doi:10.1007/s00170-018-2002-1

Cited by 19 publications

(24 citation statements)

References 30 publications

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“…The materials properties used in the model were shown in our previous studies [14]. Shen et al demonstrated that, during ultrasonic spot welding, when the peaks of the sonotrode tip is exerted on the top sheet surface, resulting in the distinctdifferent stress distribution, and the stress below the peak of the sonotrode tip is higher than that below the sonotrode tip valley [15].…”

Section: Materials and Experimental Proceduresmentioning

confidence: 99%

Characteristics of ultrasonic spot welding of Cu/Ni dissimilar metals

Liu

et al. 2021

Science and Technology of Welding and Joining

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With increasing clamping pressure, the bond density increases, the effective thickness decreases, and the plastic deformation at the Cu side near the welding interface regions below the sonotrode tip peak and valley increases; the maximum lap shear tensile load is obtained at the clamping pressure of 0.5 MPa. In the case of the Cu/Ni joint prepared at the clamping pressure of 0.5 MPa, evident mutual diffusion and nanoscale wave-like pattern appear in the Cu/Ni interfacial area, bonding between Cu and Ni sheets is formed by the interdiffusion of the parent elements. Plastic strain distribution and temperature on weld cross-section were simulated employing finite element analysis.

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Section: Materials and Experimental Proceduresmentioning

confidence: 99%

Characteristics of ultrasonic spot welding of Cu/Ni dissimilar metals

Liu

et al. 2021

Science and Technology of Welding and Joining

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“…Ultrasonic vibration energy Q USW , is converted into friction heat Q f and plastic deformation heat Q q [18], as shown in Equation (2):…”

Section: The Principle Of Hybrid Weldingmentioning

confidence: 99%

“…In RUSW, material softening arises from two sources: Ultrasonic softening and thermal softening [19]. Thus, the material softening rate in the welding process can be expressed as [18]:…”

Section: The Principle Of Hybrid Weldingmentioning

confidence: 99%

Microstructure and Mechanical Properties of Resistance Heat-Assisted High-Power Ultrasonic Dissimilar Welded Cu/Al Joint

Biao

2019

Metals

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The Cu/Al dissimilar joint, welded by high-power ultrasonic welding technology, is still facing challenges despite the significant research attention it has attracted. In this work, the microstructure and mechanical properties of resistance heat-assisted high-power ultrasonic welding of Cu/Al are investigated, in order to obtain high-quality joints. The intermetallic compound (IMC) at the interface of hybrid welding is primarily composed of Al2Cu, and the additional resistance of heat reduces the thickness of this brittle IMC layer. The average shear stress for the joint prepared by hybrid welding is~97 MPa, which is higher compared to the joint strength without resistance heat (90 MPa). Moreover, the duration of the hybrid welding process is shorter. Finally, the fracture of the hybrid weld is found to be a brittle-ductile hybrid mode.

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“…Solid state ultrasonic bonding renders it possible to bond similar and dissimilar materials directly and within a short duration [1][2][3][4][5][6]. Al ribbon bonding is applied to power electronics packaging as well as to Al wire bonding [1,[6][7][8].…”

Section: Introductionmentioning

confidence: 99%

“…Because the bonding interface is typically invisible, it is not simple to directly observe the bonding interface during the bonding process. Therefore, in general, off-line observations of the bonded interface have been implemented [1,2,11,12,14,15,17,19,22,28]; in lieu of this, numerical analyses of bonding processes have been performed [4,13,18,[34][35][36][37][38][39]. A few studies Annealed pure aluminum ribbon made by Tanaka Denshi Kogyo, Japan was used in the present study.…”

Section: Introductionmentioning

confidence: 99%

In-Situ Observation of Adhesion Behavior During Ultrasonic Al Ribbon Bonding

et al. 2019

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In-situ observation was performed on a transparent silica substrate during ultrasonic Al ribbon bonding, using a high-speed video camera with differing frame rates, 10 4 fps and 10 3 fps, to clarify the adhesion behavior. The bonding process was observed as follows. Initially, friction slip occurred, producing multiple island streaks in the direction parallel to the ultrasonic vibration. The island streaks were formed as a scratch, due to surface waviness of the Al ribbon. Momentarily, a belt-shaped bond zone was formed at the center, normally due to the ultrasonic vibration. The island streaks could be clearly observed at 10 4 fps. However, the central belt zone was unclear and appeared translucent at 10 4 fps; although it was clear when observed at 10 3 fps. The island streaks were unclear at 10 3 fps. The positional relation of the island streaks and the central belt zone was confirmed from in-situ observation results of a twist and peel test of Al ribbon bonded to silica substrate. The central belt zone was between the island streaks and the silica substrate.

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Modeling of high-power ultrasonic welding of Cu/Al joint

Cited by 19 publications

References 30 publications

Characteristics of ultrasonic spot welding of Cu/Ni dissimilar metals

Characteristics of ultrasonic spot welding of Cu/Ni dissimilar metals

Microstructure and Mechanical Properties of Resistance Heat-Assisted High-Power Ultrasonic Dissimilar Welded Cu/Al Joint

In-Situ Observation of Adhesion Behavior During Ultrasonic Al Ribbon Bonding

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