Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding
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...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-01-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/6/1/6 |
| _version_ | 1797479026676203520 |
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| author | Rafael Gomes Nunes Silva Sylvia De Meester Koen Faes Wim De Waele |
| author_facet | Rafael Gomes Nunes Silva Sylvia De Meester Koen Faes Wim De Waele |
| author_sort | Rafael Gomes Nunes Silva |
| collection | DOAJ |
| description | 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. |
| first_indexed | 2024-03-09T21:40:00Z |
| format | Article |
| id | doaj.art-46871e693a8b45e797208b0d06857581 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-09T21:40:00Z |
| publishDate | 2022-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-46871e693a8b45e797208b0d068575812023-11-23T20:33:35ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942022-01-0161610.3390/jmmp6010006Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar WeldingRafael Gomes Nunes Silva0Sylvia De Meester1Koen Faes2Wim De Waele3Belgian Welding Institute, 9050 Ghent, BelgiumDepartment of Electromechanical, Systems and Material Engineering, Ghent University, 9050 Ghent, BelgiumBelgian Welding Institute, 9050 Ghent, BelgiumDepartment of Electromechanical, Systems and Material Engineering, Ghent University, 9050 Ghent, BelgiumThe 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.https://www.mdpi.com/2504-4494/6/1/6Cu–Al weldingmetallographic examinationparameter optimisationtensile strengthUSW |
| spellingShingle | Rafael Gomes Nunes Silva Sylvia De Meester Koen Faes Wim De Waele Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding Journal of Manufacturing and Materials Processing Cu–Al welding metallographic examination parameter optimisation tensile strength USW |
| title | Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding |
| title_full | Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding |
| title_fullStr | Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding |
| title_full_unstemmed | Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding |
| title_short | Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding |
| title_sort | development and evaluation of the ultrasonic welding process for copper aluminium dissimilar welding |
| topic | Cu–Al welding metallographic examination parameter optimisation tensile strength USW |
| url | https://www.mdpi.com/2504-4494/6/1/6 |
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