Performance Prediction for Ultrasonically Welded Dissimilar Materials Joints

2016 ◽  
Vol 139 (1) ◽  
Author(s):  
Liang Xi ◽  
Mihaela Banu ◽  
S. Jack Hu ◽  
Wayne Cai ◽  
Jeffrey Abell
Keyword(s):  
Failure Modes ◽  
Mechanical Performance ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Lithium Ion ◽  
Microscopic Analysis ◽  
Lap Shear ◽  
Physical Attributes ◽  
Assembly Operations ◽  
Metal Welding

Ultrasonic metal welding has been used to join multiple layers of battery tabs with the bus bar in lithium-ion battery assembly operations. This paper describes joint performance models for ultrasonic metal welds of multiple layers of dissimilar battery tab materials, i.e., aluminum and copper. Finite element (FE) models are developed to predict the mechanical performance of the ultrasonically welded joints. The models predict peak shear load, energy absorption capability, and failure modes, which are necessary for modeling product performance and defining process requirements for the welds. The models can be adjusted to represent different quality of welds created in conditions of underweld (UW), normal-weld (NW), or overweld (OW) using physical attributes observed through microscopic analysis. The models are validated through lap shear tests, which demonstrate excellent agreement for the maximum force in the NW condition and good agreement for the UW and OW conditions. The models provide in-depth understanding of the relationship among welding process parameters, physical weld attributes, and the weld performance. The models also provide significant insight for further development of ultrasonic welding process for battery tabs and help optimize welding process for more than four-layered joints.

scholarly journals A Quality Study of a Self-Piercing Riveted Joint between Vibration-Damping Aluminum Alloy and Dissimilar Materials

2020 ◽  
Vol 10 (17) ◽  
pp. 5947
Author(s):  
Dong Hyuck Kam ◽  
Taek Eon Jeong ◽  
Jedo Kim
Keyword(s):  
Aluminum Alloy ◽  
Failure Modes ◽  
Mechanical Performance ◽  
Dissimilar Materials ◽  
Vibration Damping ◽  
Shear Load ◽  
Load Testing ◽  
Tensile Shear ◽  
Reinforced Plastic ◽  
Riveted Joints

This study investigates the quality of self-piercing riveted joints between vibration-damping aluminum (Al) and other dissimilar materials, namely aluminum alloy (AL5052-H32), steel alloy (GA590DP), and carbon-reinforced plastic (CFRP). The effects of die types (flat, cone, and nipple) on the geometrical characteristics and mechanical performance of the joints are studied using a cross-section examination and tensile shear load testing. The failure modes of each joint are also presented, showing the nature of the forces leading to the joint failures. The results indicate that, for all configurations, adequate joining between vibration-damping Al with AL5052-H32 is expected with a maximum shear load up to 3.28 kN. A shear load up to 3.6 kN was measured for the joints with GA590DP panels with acceptable top and bottom seal characteristics. A vibration-damping Al panel can only be positioned at the bottom when riveting with CFRP due to the brittle nature of CFRP. A tensile shear load up to 2.26 kN was found, which is the lowest amongst the materials tested in this study.

scholarly journals Dynamic Behavior of Self-Piercing Riveted and Mechanical Clinched Joints of Dissimilar Materials: An Experimental Comparative Investigation

2019 ◽  
Vol 2019 ◽  
pp. 1-12 ◽  
Author(s):  
Yulong Ge ◽  
Yong Xia
Keyword(s):  
Mechanical Behavior ◽  
Failure Modes ◽  
Dissimilar Materials ◽  
Dynamic Effect ◽  
Comparative Investigation ◽  
Rate Dependent ◽  
Lap Shear ◽  
Baking Process ◽  
Before And After ◽  
Peel Tests

The present work compares the dynamic effect of a self-piercing riveted (SPR) joint with that of a mechanical clinched joint having the dissimilar materials combination. The substrates used in this investigation are aluminum alloy AA5182-O and deep drawing steel DX51D+Z. The static and dynamic behaviors and the failure modes of the SPR and clinching joints are characterized by lap-shear, cross-tension, and coach-peel tests. The influence of the strain-rate-dependent mechanical behavior of the substrates on the joints is examined; this can help improve prediction of the energy absorption of the joints under impact loading. Considering the realistic baking process in a painting shop, the deforming and hardening effects on the SPR and the clinched joints induced by baking are also studied. The specimens are heated to 180°C for 30 min in an oven and then cooled down in air. The SPR and the clinched joints before and after the baking process are compared in terms of the mechanical behavior.

Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
Dongkyun Lee ◽  
Elijah Kannatey-Asibu ◽  
Wayne Cai
Keyword(s):  
Lithium Ion Battery ◽  
Automotive Industry ◽  
Semiconductor Industry ◽  
Computational Cost ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Lithium Ion ◽  
Ultrasonic Welding ◽  
Simulation Procedure ◽  
Thermal Phenomena

Ultrasonic welding is a solid-state bond created using ultrasonic energy. It has been used in the semiconductor industry for several decades, and more recently, in the automotive industry such as for lithium-ion battery welding. Although there existed numerical simulations for ultrasonic welding, the models were limited to two-layer and like materials stackups. In this study, finite element theories are introduced and simulation procedure is established for multiple sheets and dissimilar metal ultrasonic welding. The procedures require both abaqus/Standard and abaqus/Explicit to simulate the coupled mechanical-thermal phenomena over the entire weld duration with moderate computational cost. The procedure is verified and used to simulate selected specific cases involving multiple sheets and dissimilar materials, i.e., copper and aluminum. The simulation procedure demonstrates its capability to predict welding energy, distortion, and temperature distribution of the workpieces. Case studies of ultrasonic welding simulations for multiple layers of lithium-ion battery tabs are presented. The prediction leads to several innovative ultrasonic welding process designs for improved welding quality.

scholarly journals The dangers of single-lap shear testing in understanding polymer composite welded joints

2021 ◽  
Vol 379 (2203) ◽  
pp. 20200296 ◽  
Author(s):  
Irene Fernandez Villegas ◽  
Calvin Rans
Keyword(s):  
Polymer Composite ◽  
Welded Joints ◽  
Failure Modes ◽  
Local Heating ◽  
Welding Process ◽  
Joint Mechanics ◽  
Process Testing ◽  
Lap Shear ◽  
Design Values ◽  
Welding Processes

Single-lap shear (SLS) joints are straightforward to manufacture. This makes them especially attractive for testing polymer composite welded joints. Owing to local heating, which is characteristic of composite welding processes, the production of more geometrically intricate joints (such as double-lap or scarfed joints) or bigger joints (such as end-notched flexure or double cantilever beam) typically entails significant complexity in the design of the welding process. Testing of SLS joints is also uncomplicated and, even though, owing to mixed-mode loading and uneven stress distribution, it does not provide design values, it is widely acknowledged as a valuable tool for comparison. Even so, comparing different aspects of composite welded joints through their corresponding SLS strength values alone can be deceptive. This paper shows that comparison of different welding processes, adherend materials, process parameters or different types of joining techniques through SLS testing is only meaningful when strength values are combined with knowledge on other aspects of the joints such as joint mesostructure, failure modes and joint mechanics. This article is part of a discussion meeting issue ‘A cracking approach to inventing new tough materials: fracture stranger than friction’.

Characterization of Ultrasonic Metal Welding by Correlating Online Sensor Signals With Weld Attributes

2014 ◽  
Author(s):  
S. Shawn Lee ◽  
Chenhui Shao ◽  
Tae Hyung Kim ◽  
S. Jack Hu ◽  
Elijah Kannatey-Asibu ◽  
...  
Keyword(s):  
Welding Process ◽  
Deep Understanding ◽  
Lithium Ion ◽  
Ultrasonic Welding ◽  
Diagnostic Methods ◽  
Quality Monitoring ◽  
Process Conditions ◽  
Ultrasonic Metal Welding ◽  
Bond Density ◽  
Metal Welding

Online process monitoring in ultrasonic welding of automotive lithium-ion batteries is essential for robust and reliable battery pack assembly. Effective quality monitoring algorithms have been developed to identify out of control parts by applying purely statistical classification methods. However, such methods do not provide the deep physical understanding of the manufacturing process that is necessary to provide diagnostic capability when the process is out of control. The purpose of this study is to determine the physical correlation between ultrasonic welding signal features and the ultrasonic welding process conditions and ultimately joint performance. A deep understanding in these relationships will enable a significant reduction in production launch time and cost, improve process design for ultrasonic welding, and reduce operational downtime through advanced diagnostic methods. In this study, the fundamental physics behind the ultrasonic welding process is investigated using two process signals, weld power and horn displacement. Several online features are identified by examining those signals and their variations under abnormal process conditions. The joint quality is predicted by correlating such online features to weld attributes such as bond density and post-weld thickness that directly impact the weld performance. This study provides a guideline for feature selection and advanced diagnostics to achieve a reliable online quality monitoring system in ultrasonic metal welding.

Ultrasonic plastic welding of CF/PA6 composites to aluminium: Process and mechanical performance of welded joints

2019 ◽  
Vol 53 (18) ◽  
pp. 2607-2621 ◽  
Author(s):  
Umberto F Dal Conte ◽  
Irene F Villegas ◽  
Julien Tachon
Keyword(s):  
Mechanical Performance ◽  
Lightweight Design ◽  
Welding Process ◽  
Thermoplastic Composites ◽  
Process Time ◽  
Reinforced Plastics ◽  
Lap Shear ◽  
Physical Treatments ◽  
Reinforced Thermoplastics ◽  
Plastic Welding

Due to environmental challenges and need for action with regard to CO2 emission, reducing the weight of vehicles has become one of the most important goals of car manufacturers in Europe. Materials like fibre-reinforced plastics and aluminium are the core of the research for lightweight design. However, efficiently joining these materials together is still a challenge. When thermoplastic composites are used, direct joining (i.e. without adhesives or fasteners) with the metal substrate can be obtained using welding technologies which melt the thermoplastic at the interface. In this study, ultrasonic plastic welding was investigated as a candidate technology for joining aluminium and carbon fibre-reinforced thermoplastics. The goal was to understand the main mechanisms involved in the welding process and how they affect the performance of the joint. Initially, the technique proved to be successful, but moderate strengths were obtained. Therefore, several surface pre-treatments of aluminium were analysed to improve the performance in terms of lap shear strength; mechanical, chemical and physical treatments were also carried out. With laser structuring, strengths comparable to adhesive bonded joints were obtained, but in a much shorter process time. Other treatments led to considerable improvements as well. The encouraging results achieved represent an important step in the development of ultrasonic plastic welding for multi-material joining in the automotive industry.

Classification of Failure Modes in Friction Stir Blind Riveted Lap-Shear Joints With Dissimilar Materials

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Wei-Ming Wang ◽  
Haris Ali Khan ◽  
Jingjing Li ◽  
Scott F. Miller ◽  
A Zachary Trimble
Keyword(s):  
Failure Modes ◽  
Dissimilar Materials ◽  
Polymeric Composite ◽  
Tensile Tests ◽  
Great Promise ◽  
Lightweight Structures ◽  
Friction Stir ◽  
Lap Shear ◽  
Transportation Sector ◽  
Static Tensile

In transportation sector, there is an increasing need for joining dissimilar materials for lightweight structures; however, substantial barriers to the joining of dissimilar materials have led to an investigation and development of new joining techniques. Friction stir blind riveting (FSBR), a newly invented method, has shown great promise in joining complex structures with dissimilar materials. The process can be utilized more effectively if knowledge regarding the failure mechanisms of the FSBR joints becomes available. This research focuses on investigating the different mechanisms that lead to a failure in FSBR joints under lap-shear tensile tests. An in situ, nondestructive, acoustic emission (AE) testing method was applied during quasi-static tensile tests to monitor the initiation and evolution of damage in FSBR joints with different combinations of dissimilar materials (including aluminum, magnesium, and a carbon-fiber reinforced polymeric composite). In addition, a fractographic analysis was conducted to characterize the failure modes. Finally, based on the analysis, the distinct failure modes and damage accumulation processes for the joints were identified. An AE accumulative hit history curve was found to be efficient to discriminate the deformation characteristics, such as the deformation zone and failure mode, which cannot be observed through a traditional extensometer measurement method. In addition, the AE accumulative hit history curve can be applied to predict the failure extension or moment of FSBR joints through an identification of the changes in curve slope. Such slope changes usually occur around the middle of Zone II, which is defined in this study.

Characterization of Ultrasonic Metal Welding by Correlating Online Sensor Signals With Weld Attributes

2014 ◽  
Vol 136 (5) ◽  
Author(s):  
S. Shawn Lee ◽  
Chenhui Shao ◽  
Tae Hyung Kim ◽  
S. Jack Hu ◽  
Elijah Kannatey-Asibu ◽  
...  
Keyword(s):  
Welding Process ◽  
Deep Understanding ◽  
Lithium Ion ◽  
Ultrasonic Welding ◽  
Diagnostic Methods ◽  
Quality Monitoring ◽  
Process Conditions ◽  
Ultrasonic Metal Welding ◽  
Bond Density ◽  
Metal Welding

Online process monitoring in ultrasonic welding of automotive lithium-ion batteries is essential for robust and reliable battery pack assembly. Effective quality monitoring algorithms have been developed to identify out of control parts by applying purely statistical classification methods. However, such methods do not provide the deep physical understanding of the manufacturing process that is necessary to provide diagnostic capability when the process is out of control. The purpose of this study is to determine the physical correlation between ultrasonic welding signal features and the ultrasonic welding process conditions and ultimately joint performance. A deep understanding in these relationships will enable a significant reduction in production launch time and cost, improve process design for ultrasonic welding, and reduce operational downtime through advanced diagnostic methods. In this study, the fundamental physics behind the ultrasonic welding process is investigated using two process signals, weld power and horn displacement. Several online features are identified by examining those signals and their variations under abnormal process conditions. The joint quality is predicted by correlating such online features to weld attributes such as bond density and postweld thickness that directly impact the weld performance. This study provides a guideline for feature selection and advanced diagnostics to achieve a reliable online quality monitoring system in ultrasonic metal welding.

Microstructural and Joint Analysis of Ultrasonic Welded Aluminum to Cupro-Nickel Sheets for Lithium-Ion Battery Packs

2020 ◽  
Vol 978 ◽  
pp. 463-469
Author(s):  
Soumyajit Das ◽  
Mantra Prasad Satpathy ◽  
Bharat Chandra Routara ◽  
Susanta Kumar Sahoo
Keyword(s):  
Bond Strength ◽  
Lithium Ion Battery ◽  
Welding Process ◽  
Lithium Ion ◽  
Joint Analysis ◽  
Shop Floor ◽  
Ultrasonic Frequency ◽  
Ultrasonic Metal Welding ◽  
Battery Packs ◽  
Metal Welding

Energy crisis poses a major challenge in the modern industrial scenario. A critical aspect of the shop floor work includes the welding of dissimilar metal sheets which require the right amount of energy. In order to tackle these challenges, a conservative and energy efficient method are necessary. Recently, automotive industries have been widely adopted the ultrasonic metal welding process for assembling lithium-ion battery packs and its modules. The joining of these dissimilar metals using any other conventional welding process is extremely challenging due to varying physical, chemical, thermal properties, the formation of the heat affected zone and lesser bond strength. However, ultrasonic metal welding yields better quality welds under the influence of optimal parametric conditions. In this research, the weld quality of two dissimilar materials, namely, aluminum (AA1060) with cupronickel (C71500) sheets investigated at different welding time, vibration amplitudes and welding pressures with a fixed ultrasonic frequency of 20 kHz. Experimental results show the tensile shear strength of the weld is maximum at the highest vibration amplitude with a moderate amount of weld pressure and weld time. Additionally, the joint quality and its associated microstructure at the weld region are analyzed by scanning electron microscopy (SEM) to reveal the bond strength with the interlocking feature.

Microstructure and Mechanical Performance of Cold Metal Transfer Spot Joints of AA6061-T6 to Galvanized DP590 Using Edge Plug Welding Mode

2016 ◽  
Vol 138 (7) ◽  
Author(s):  
Haiyang Lei ◽  
Yongbing Li ◽  
Blair E. Carlson ◽  
Zhongqin Lin
Keyword(s):  
Mechanical Performance ◽  
Welding Process ◽  
Metal Transfer ◽  
Weld Nugget ◽  
Weld Strength ◽  
Welding Parameters ◽  
Feed Speed ◽  
Cold Metal Transfer ◽  
Lap Shear ◽  
Cold Metal

Dissimilar joining of aluminum to steel poses a challenge for arc welding. In this study, aluminum AA6061-T6 and hot dipped galvanized DP590 steel were joined using the Fronius cold metal transfer (CMT) welding process applying an edge plug welding mode (EPW). The correlation of the welding parameters, weld characteristics, and weld strength was systematically investigated. It was found that the EPW mode created a zinc-rich zone at the weld root along the Al–steel faying interface which transitioned to a continuous and compact intermetallic compounds (IMC) layer in the middle portion of the joint. The fracture propagation in lap-shear specimens was affected by this increase of IMC layer thickness. At a wire feed speed (wfs) of 5.6 m/min, the fracture initiated along the zinc-rich layer at the faying interface and then, upon meeting the compact IMC layer, propagated into the aluminum weld nugget. Propagation followed a path within the weld nugget along the boundary between columnar and equiaxed grains leading to weld nugget pullout upon fracture. For IMC layer peak thicknesses below 10 μm, the strength increased as a function of weld nugget diameter. However, larger heat inputs resulted in IMC layer thicknesses greater than 10 μm and interfacial fracture.

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