In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties
Ultrasonic metal welding (USMW) is widely used in assembling lithium-ion (Li-ion) battery packs due to its advantages in joining dissimilar and conductive materials in the solid state. However, the welding process and mechanisms are not yet clearly understood. In this study, dissimilar joints of alu...
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MDPI AG
2023-04-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/8/3033 |
| _version_ | 1797604550128959488 |
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| author | Junqi Li Johannes Zillner Frank Balle |
| author_facet | Junqi Li Johannes Zillner Frank Balle |
| author_sort | Junqi Li |
| collection | DOAJ |
| description | Ultrasonic metal welding (USMW) is widely used in assembling lithium-ion (Li-ion) battery packs due to its advantages in joining dissimilar and conductive materials in the solid state. However, the welding process and mechanisms are not yet clearly understood. In this study, dissimilar joints of aluminum alloy EN AW 1050 to copper alloy EN CW 008A were welded by USMW to simulate the tab-to-bus bar interconnects for Li-ion battery assembly. Qualitative and quantitative investigations were carried out on plastic deformation, microstructural evolution, and the correlated mechanical properties. During USMW, the plastic deformation concentrated on the Al side. The thickness of Al was reduced by more than 30%; complex dynamic recrystallization and grain growth occurred near the weld interface. The mechanical performance of the Al/Cu joint was evaluated with the tensile shear test. The failure load gradually increased until a welding duration of 400 ms, and then remained almost constant. The obtained results showed that the mechanical properties were greatly influenced by plastic deformation and microstructure evolution, which provides guidance for improving the weld quality and the process in general. |
| first_indexed | 2024-03-11T04:47:53Z |
| format | Article |
| id | doaj.art-b3c9c674dfdb4caa967a44dd5a83c3fd |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T04:47:53Z |
| publishDate | 2023-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-b3c9c674dfdb4caa967a44dd5a83c3fd2023-11-17T20:12:07ZengMDPI AGMaterials1996-19442023-04-01168303310.3390/ma16083033In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical PropertiesJunqi Li0Johannes Zillner1Frank Balle2Walter-and-Ingeborg-Herrmann Chair for Power Ultrasonics and Engineering of Functional Materials, Department of Sustainable Systems Engineering (INATECH), Faculty of Engineering, University of Freiburg, 79110 Freiburg, GermanyWalter-and-Ingeborg-Herrmann Chair for Power Ultrasonics and Engineering of Functional Materials, Department of Sustainable Systems Engineering (INATECH), Faculty of Engineering, University of Freiburg, 79110 Freiburg, GermanyWalter-and-Ingeborg-Herrmann Chair for Power Ultrasonics and Engineering of Functional Materials, Department of Sustainable Systems Engineering (INATECH), Faculty of Engineering, University of Freiburg, 79110 Freiburg, GermanyUltrasonic metal welding (USMW) is widely used in assembling lithium-ion (Li-ion) battery packs due to its advantages in joining dissimilar and conductive materials in the solid state. However, the welding process and mechanisms are not yet clearly understood. In this study, dissimilar joints of aluminum alloy EN AW 1050 to copper alloy EN CW 008A were welded by USMW to simulate the tab-to-bus bar interconnects for Li-ion battery assembly. Qualitative and quantitative investigations were carried out on plastic deformation, microstructural evolution, and the correlated mechanical properties. During USMW, the plastic deformation concentrated on the Al side. The thickness of Al was reduced by more than 30%; complex dynamic recrystallization and grain growth occurred near the weld interface. The mechanical performance of the Al/Cu joint was evaluated with the tensile shear test. The failure load gradually increased until a welding duration of 400 ms, and then remained almost constant. The obtained results showed that the mechanical properties were greatly influenced by plastic deformation and microstructure evolution, which provides guidance for improving the weld quality and the process in general.https://www.mdpi.com/1996-1944/16/8/3033ultrasonic weldingdissimilar jointsplastic deformationmicrostructure |
| spellingShingle | Junqi Li Johannes Zillner Frank Balle In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties Materials ultrasonic welding dissimilar joints plastic deformation microstructure |
| title | In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties |
| title_full | In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties |
| title_fullStr | In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties |
| title_full_unstemmed | In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties |
| title_short | In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties |
| title_sort | in depth evaluation of ultrasonically welded al cu joint plastic deformation microstructural evolution and correlation with mechanical properties |
| topic | ultrasonic welding dissimilar joints plastic deformation microstructure |
| url | https://www.mdpi.com/1996-1944/16/8/3033 |
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