Influence of process parameters on microstructure and mechanical properties in high power ultrasonic welding of Cu/Al

LI Huan; ZHOU Kang; ZHANG Jinzhou; YANG Xiong; CAO Biao

doi:10.12073/j.hjxb.20191029002

TRANSACTIONS OF THE CHINA WELDING INSTITUTION > 2020 > 41(4): 20-25. > DOI: 10.12073/j.hjxb.20191029002

LI Huan, ZHOU Kang, ZHANG Jinzhou, YANG Xiong, CAO Biao. Influence of process parameters on microstructure and mechanical properties in high power ultrasonic welding of Cu/Al[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2020, 41(4): 20-25. DOI: 10.12073/j.hjxb.20191029002

Citation:

PDF (27312 KB)

Influence of process parameters on microstructure and mechanical properties in high power ultrasonic welding of Cu/Al

1.
Yangtze University, Jingzhou, 434023, China
2.
South China University of Technology, Guangzhou, 510640, China
3.
Beijing Institute of Technology, Beijing, 100081, China

More Information

Received Date: October 28, 2019
Available Online: July 26, 2020

Graphical Abstract

Abstract

Abstract

Although high power ultrasonic spot welding(USW) can obtain better welding quality about highly conductive materials, the welding mechanism is still unclear. To improve the understanding of the USW process and to enhance the weld strength in similar Cu/Al welding, the effect of clampling force, welding time, vibration amplitude and profile of the sonotrode tips on the temperature rise, intermetallic compound (IMC) growth of welding interface and mechanical properties of joint during Cu/Al high power ultrasonic welding process are investigared. Increasing of clampling force, the thickness of the IMC first increases and then decreases. The interface temperature decreases and the thickness of the IMC decreases linearly with vibration amplitude. The optimal number of welding head teeth is 9. Increasing and decreasing the number of sonotrode teeth will lead to lower interface temperature and formation of welding cracks. In order to obtain high welding quality of Cu/Al joint, the vibration amplitude sholud be set to its maximum. Scanning electron microscopy (SEM) test is performed on the fracture of the Cu/Al joint and shows that the fracture of Cu/Al ultrasonic welded joint is ductile-brittle hybrid mode. The research results provide guidance for optimizing the ultrasonic welding parameters.
- ultrasonic welding,
- dissimilar metals,
- intermetallic compound,
- mechanical property

FullText(HTML)

References (16)

References

Bakavos D, Prangnell P B. Mechanisms of joint and microstructure formation in high power ultrasonic spot welding 6111 aluminium automotive sheet[J]. Materials Science and Engineering A, 2010, 527(23): 6320 − 6334. doi: 10.1016/j.msea.2010.06.038

Zhang Changqing, Lü Guangming, Jin Xin, et al. Study of joining mechanism of ABS polymer and steel/aluminum by resistance spot welding[J]. China Welding, 2018, 27(2): 57 − 61.

Li Huan, Cao Biao, Liu Jian, et al. Modeling of high-power ultrasonic welding of Cu/Al joint[J]. The International Journal of Advanced Manufacturing Technology, 2018, 97(1−4): 833 − 844. doi: 10.1007/s00170-018-2002-1

Ni Z L, Yang J J, Gao Z T, et al. Joint formation in ultrasonic spot welding of aluminum to copper and the effect of particle interlayer[J]. Journal of Manufacturing Processes, 2020, 50(2): 57 − 67.

Zhang Z, Wang K, Li J, et al. Investigation of interfacial layer for ultrasonic spot welded aluminum to copper joints[J]. Scientific Reports, 2017, 7(1): 12505. doi: 10.1038/s41598-017-12164-2

Wang G Q, Zhao Y H, Zhang L N, et al. A new weld repair technique for friction stir welded aluminium structure: inertia friction pull plug welding[J]. China Welding, 2017, 26(4): 56 − 64.

Shakil M, Tariq N H, Ahmad M, et al. Effect of ultrasonic welding parameters on microstructure and mechanical properties of dissimilar joints[J]. Materials & Design, 2014, 55(3): 263 − 273.

Nong L, Shao C, Kim T H, et al. Improving process robustness in ultrasonic metal welding of lithium-ion batteries[J]. Journal of Manufacturing Systems, 2018, 48(7): 45 − 54.

李东, 赵杨洋, 张延松. 焊接能量对铝/铜超声波焊接接头显微组织的影响[J]. 焊接学报, 2014, 35(2): 47 − 50.

Li Dong, Zhao Yangyang, Zhang Yansong. Effect of welding energy on microstructures of the Al/Cu joints obtained by ultrasonic welding[J]. Transactions of the China Welding Institution, 2014, 35(2): 47 − 50.

解龑, 冯梦楠, 罗震. 齿形对超声波焊接泡沫镍薄板与实体铝薄板的影响[J]. 焊接学报, 2018, 39(12): 5 − 8. doi: 10.12073/j.hjxb.2018390288

Xie Yan, Feng Mengnan, Luo Zhen. Effect of teeth shape on ultrasonic spot welding joints of nickel foam sheet and aluminum solid sheet[J]. Transactions of the China Welding Institution, 2018, 39(12): 5 − 8. doi: 10.12073/j.hjxb.2018390288

Feng M N, Xie Y, Zhao C F, et al. Microstructure and mechanical performance of ultrasonic spot welded open-cell Cu foam/Al joint[J]. Journal of Manufacturing Processes, 2018, 33(6): 86 − 95.

Li Huan, Cao Biao, Yang Jingwei, et al. Modeling of resistance heat assisted ultrasonic welding of Cu-Al joint[J]. Journal of Materials Processing Technology, 2018, 256(6): 121 − 130.

Satpathy M P, Sahoo S K. Mechanical performance and metallurgical characterization of ultrasonically welded dissimilar joints[J]. Journal of Manufacturing Processes, 2017, 25(1): 443 − 451.

Bergmann J P, Regensburg A, Schürer R, et al. Effect of the interface characteristics on the joint properties and diffusion mechanisms during ultrasonic metal welding of Al/Cu[J]. Welding in the World, 2017, 61(3): 499 − 506. doi: 10.1007/s40194-017-0449-6

Satpathy M P, Mohapatra K D, Sahoo S K. Ultrasonic spot welding of Al-Cu dissimilar metals: a study on parametric influence and thermo-mechanical simulation[J]. International Journal of Modelling and Simulation, 2018, 38(2): 83 − 95. doi: 10.1080/02286203.2017.1395198

Yang J, Cao B, Lu Q. The effect of welding energy on the microstructural and mechanical properties of ultrasonic-welded copper joints[J]. Materials, 2017, 10(2): 1 − 13.

[1]	XUE Hongyu, LONG Weimin, JIU Yongtao, CHENG Zhan, HUANG Guoqin, ZHANG Fenglin. Microstructure and mechanical properties of aluminum/AlSiNi/steel joint by induction brazing[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2020, 41(3): 45-49. DOI: 10.12073/j.hjxb.20190128001
[2]	ZHANG Man1, ZHANG Jun1, JIANG Teng1, ZHANG Lincai2, YANG Dachun1, HOU Yu1, WU Jing1. Effect of Fe-Al intermetallic compound on mechanical property of aluminum/steel brazed joint[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2018, 39(1): 61-64. DOI: 10.12073/j.hjxb.2018390014
[3]	QIU Xiliang, WANG Qian, LIN Tiesong, HE Peng, LU Fengjiao. Effect of Al18B4O33 whiskers on microstructure evolution of intermetallic compound layer and shear behavior of soldered joint[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2015, 36(8): 35-38.
[4]	QIN Fei, AN Tong, ZHONG Weixu, LIU Chengyan. Nanoindentation properties of intermetallic compounds in lead-free solder joints[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2013, (1): 25-28,32.
[5]	LV Shixiong, JING Xiaojun, HUANG Yongxian, CHENG Jinli, ZHENG Chuanqi. Interfacial characteristic and property of Ti/Al dissimilar alloys joint with arc welding-brazing[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2012, (6): 23-26.
[6]	ZHU Hai, ZHENG Haiyang, GUO Yarding. Effects of heat treatment technology on mechanical properties of friction welding drill rod[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2008, (12): 93-96.
[7]	TAI Feng, GUO Fu, SHEN Hao, Han Mengting. Effect of heating rate on microstructure and mechanical properties of composite solder joints[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2008, (9): 79-82.
[8]	YAO Wei, GONG Shui-li, CHEN Li. Microstructure and mechanical properties of laser welded joint of titanium alloy[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2006, (2): 69-72,76.
[9]	Sun Daqian, Zhou Zhenfeng, Ren Zhenan. Microstructure and Mechanical Properties of Austempered Ductile Iron Welds[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 1995, (4): 202-207.
[10]	Shi Yaowu, Zhou Ningning, Zhang Xinping, Tang Wei, Lei Yongping. Microshear test and its evaluation to mechanical properties of welded joints[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 1994, (4): 235-240.

Cited By

Cited by

Periodical cited type(8)

1.	邵文杰，丁云龙，刘冰洋，庄志国，韩冰. 焊接温度对Cu/Al真空扩散焊接接头组织与性能的影响. 材料热处理学报. 2025(04): 218-225 .
2.	成先明，杨可，邵壮，王健，黄思蜀，张鑫. 超声波焊接能量对铜/铝导线接头结合性能的影响. 焊接学报. 2024(04): 65-70+132-133 . 本站查看
3.	张义磊. 压力容器内壁涂层的耐磨与耐腐蚀性能研究. 化工装备技术. 2023(01): 69-71 .
4.	李欢，黄朝望，周亢，张长鑫，曾才有. 铝/钢大功率超声波焊接过程模拟与试验验证. 中国机械工程. 2022(02): 226-233 .
5.	宋一诺，曲杰，王廷. Cu/Al/Cu层状金属复合材料电子束焊接接头特征. 焊接. 2022(09): 50-54 .
6.	李欢，张长鑫，敖三三，曾才有，周亢. 辅助电流对Cu/Al大功率超声波焊接的影响. 稀有金属材料与工程. 2022(12): 4624-4631 .
7.	陆斌. 不锈钢制压力容器焊缝接头性能研究. 特种设备安全技术. 2021(04): 17-19 .
8.	章继. 超声波焊接加工质量受焊头压力的影响分析. 新型工业化. 2020(07): 95-97 .

Other cited types(2)

Get Citation

PDF

XML

Article views (650) PDF downloads (81) Cited by(10)

Turn off MathJax

Article Contents

Abstract

References

Influence of process parameters on microstructure and mechanical properties in high power ultrasonic welding of Cu/Al