Optimization of ultrasonic welding parameters for copper to copper joints using design of experiments

Elangovan, Sooriyamoorthy; Prakasan, K.; Jaiganesh, V.

doi:10.1007/s00170-010-2627-1

Cited by 73 publications

(41 citation statements)

References 7 publications

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“…The adjustable welding parameters are, above all, the pressure of the sonotrode p, the amplitude of the vibration u(t) and the welding time [18,19]. In Fig.…”

Section: Influence Of Sonotrode Pressure On Weld Qualitymentioning

confidence: 99%

Welding techniques for battery cells and resulting electrical contact resistances

Brand

Schmidt

Zaeh

et al. 2015

Journal of Energy Storage

161

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“…The adjustable welding parameters are, above all, the pressure of the sonotrode p, the amplitude of the vibration u(t) and the welding time [18,19]. In Fig.…”

Section: Influence Of Sonotrode Pressure On Weld Qualitymentioning

confidence: 99%

Welding techniques for battery cells and resulting electrical contact resistances

Brand

Schmidt

Zaeh

et al. 2015

Journal of Energy Storage

161

View full text Add to dashboard Cite

“…The measured temperature was as high as 400 • C which caused softening immediately after welding and then recovered at a rate faster than the parent material. For ultrasonic welding of copper, Elangovan et al [22] performed experimental study based on a design of experiment method, and identified several critical process parameters. The ultrasonic welding of nickel coated Cu/Cu tab was studied by Kim et al [23].…”

Section: Introductionmentioning

confidence: 99%

Microstructure, welding mechanism, and failure of Al/Cu ultrasonic welds

Cai

2015

Journal of Manufacturing Processes

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Please cite this article in press as: Wu X, et al. Microstructure, welding mechanism, and failure of Al/Cu ultrasonic welds. J Manuf Process (2015), http://dx. a b s t r a c tUltrasonic metal welding has been used widely to join battery cell terminals, or tabs (either Al or Cu), with bus bars (Cu) to form assembled battery packs in battery electric vehicles. However, the mechanism of ultrasonic welding for Al/Cu is still not well understood. In this work, the microstructures of the ultrasonic welds between three layers of lithium-ion battery tabs (either Al or Cu) and bus bars were studied. From the microstructure analysis, the weld formation mechanism and failure modes were investigated. It was found that the metal inter-mix is the main weld formation mechanism at the Al-Al interfaces, while friction-induced physical bonding is the main mechanism at Cu-Cu or Al-Cu interfaces. Metallographs also indicated that the weld failure is a combination of the interfacial debonding between the innermost tab (either Cu or Al) and the Cu bus bar and the through-thickness tearing of the tabs. The presented work provides better understanding of weld formation and failure, and hence provide insight into ultrasonic welding process toward weld quality improvement. This understanding and insight can be used to develop science-based design guidelines toward selecting the most appropriate materials and welding process parameters.

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“…The S/N ratio and means for each of the process parameters were calculated to find the influence of process parameters on the response (shear strength). In this current work, the S/N ratio was chosen according to the proposition of "the larger-the-better" characteristics that indicate its robustness according to [18]. Table 5 and Table 6.…”

Section: Signal To Noise (S/n) Ratiomentioning

confidence: 99%

Optimization of Welding Parameters for Friction Stir Lap Welding of AA6061-T6 Alloy

Rathinasuriyan¹,

Ramaiyan²,

Shanbhag³

et al. 2018

MME

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Friction Stir Welding (FSW) is currently used in many aircraft and aerospace sheet metal structures involving lap joints and there has been growing interest in recent years in utilizing this process for joining aluminum alloys. In this paper, Friction Stir Lap Welding (FSLW) of the 6061-T6 aluminum alloy was carried out to obtain the optimum welding condition for maximum shear strength where the rotational speed, axial load, and welding speed were taken as process parameters. An L-9 orthogonal array, a Taguchi Method with consideration of three levels and three factors was designed and executed for conducting trials. Analysis of variance (ANOVA) and Signal to Noise (S/N) ratio were employed to investigate the influence of different welding parameters on the shear strength and obtain the optimum parameters. The Fisher-Test was also implemented to find the design parameter which had the most important effect on the characteristic of quality. The results indicated that the tool rotational speed had the maximum percentage contribution (51%) on the response (shear strength) followed by the welding speed (38%) and the axial load (8%) while the percentage of error was 3%. However, to confirm the main effects for the means and S/N ratios of the experiment, theoretical shear strength values were computed to predict the tensile strength. The maximum shear strength of 60 MPa was achieved and the effectiveness of the method was confirmed. The optimum parameter combinations that provided higher shear strength were: rotational speed of 1200 rpm, welding speed of 45 mm/min and the axial load of 11.5 kN.

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Optimization of ultrasonic welding parameters for copper to copper joints using design of experiments

Cited by 73 publications

References 7 publications

Welding techniques for battery cells and resulting electrical contact resistances

Welding techniques for battery cells and resulting electrical contact resistances

Microstructure, welding mechanism, and failure of Al/Cu ultrasonic welds

Optimization of Welding Parameters for Friction Stir Lap Welding of AA6061-T6 Alloy

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