Micro Thin Film Sensor Embedded in Metal Structures for In-Situ Process Monitoring During Ultrasonic Welding

2005 ◽  
Author(s):  
Xudong Cheng ◽  
Xiaochun Li
Keyword(s):  
Thin Film ◽  
Heat Generation ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Weld Strength ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Thin Film Sensors ◽  
Welding Interface

The objective of this research is to develop an effective method, i.e., ultrasonic metal welding (USMW), to embed micro thin film sensors for metal tooling, and use micro thin film thermocouple study the heat generation during USMW. A complete understanding of the fundamental mechanisms of USMW does not yet exist, and the function of heat generation on weld formation is especially in argument due to the lack of the method to measure the temperature at the welding interface. Continuing on the previous preliminary study [1] which proved that thin film sensors can survive ultrasonic welding process, significant advances were made to improve sensor reliability as well as sensor fabrication effectiveness. These include the development of a new approach for batch production of the sensor units, improvement of the adhesion between metal encapsulating layers for the sensor, as well as the adhesion between the sensing layer and the dielectric layer. Welding experiments are conducted using a series of welding parameter settings with the in-situ data acquisition of temperature 50 μm away from the welding interface. Attempts are then made to correlate the heat generation to welding parameters. With the mechanical testing of the weld strength, the possibility of using heat generation as a weld strength indicator is explored.

scholarly journals Continuous ultrasonic welding of thermoplastic composites: Enhancing the weld uniformity by changing the energy director

2019 ◽  
Vol 54 (15) ◽  
pp. 2023-2035 ◽  
Author(s):  
Bram Jongbloed ◽  
Julie Teuwen ◽  
Genevieve Palardy ◽  
Irene Fernandez Villegas ◽  
Rinze Benedictus
Keyword(s):  
Thin Film ◽  
Heat Generation ◽  
High Speed ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Thermoplastic Composites ◽  
Weld Strength ◽  
Good Contact ◽  
Energy Director ◽  
Welded Seam

Continuous ultrasonic welding is a high-speed joining method for thermoplastic composites. Currently, a thin film energy director is used to focus the heat generation at the interface. However, areas of intact energy director remain in the welded seam, which significantly lowers the weld strength, and result in a non-uniformly welded seam. To improve the weld uniformity of continuous ultrasonically welded joints, we changed to a more compliant energy director. A woven polymer mesh energy director was found to give a significant improvement in weld quality. The mesh was flattened in between the composite adherends during the welding process. This flattening promoted a good contact between the energy director and the adherends, fully wetting the adherend surfaces, resulting in a more uniformly welded seam without areas of intact energy director.

Transient Temperature and Heat Flux Measurement in Ultrasonic Joining of Battery Tabs Using Thin-Film Microsensors

2013 ◽  
Vol 135 (5) ◽  
Author(s):  
Hang Li ◽  
Hongseok Choi ◽  
Chao Ma ◽  
Jingzhou Zhao ◽  
Hongrui Jiang ◽  
...  
Keyword(s):  
Thin Film ◽  
Heat Flux ◽  
Heat Generation ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Transient Temperature ◽  
Monitoring And Control ◽  
Change Rate ◽  
Flux Change ◽  
And Control

Process physics understanding, real time monitoring, and control of various manufacturing processes, such as battery manufacturing, are crucial for product quality assurance. While ultrasonic welding has been used for joining batteries in electric vehicles (EVs), the welding physics, and process attributes, such as the heat generation and heat flow during the joining process, is still not well understood leading to time-consuming trial-and-error based process optimization. This study is to investigate thermal phenomena (i.e., transient temperature and heat flux) by using micro thin-film thermocouples (TFTC) and thin-film thermopile (TFTP) arrays (referred to as microsensors in this paper) at the very vicinity of the ultrasonic welding spot during joining of three-layered battery tabs and Cu buss bars (i.e., battery interconnect) as in General Motors's (GM) Chevy Volt. Microsensors were first fabricated on the buss bars. A series of experiments were then conducted to investigate the dynamic heat generation during the welding process. Experimental results showed that TFTCs enabled the sensing of transient temperatures with much higher spatial and temporal resolutions than conventional thermocouples. It was further found that the TFTPs were more sensitive to the transient heat generation process during welding than TFTCs. More significantly, the heat flux change rate was found to be able to provide better insight for the process. It provided evidence indicating that the ultrasonic welding process involves three distinct stages, i.e., friction heating, plastic work, and diffusion bonding stages. The heat flux change rate thus has significant potential to identify the in-situ welding quality, in the context of welding process monitoring, and control of ultrasonic welding process. The weld samples were examined using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) to study the material interactions at the bonding interface as a function of weld time and have successfully validated the proposed three-stage welding theory.

Experimental Investigations on Aluminium Ultrasonic Welding Parameters

2014 ◽  
Vol 657 ◽  
pp. 306-310
Author(s):  
Lăcrămioara Apetrei ◽  
Vasile Rață ◽  
Ruxandra Rață ◽  
Elena Raluca Bulai
Keyword(s):  
Microstructural Analysis ◽  
Base Material ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Experimental Investigations ◽  
Welding Parameters ◽  
Material Structure ◽  
Welding Temperature ◽  
Wide Range ◽  
Made In

Research evolution timely tendencies, in the nonconventional technologies field, are: manufacture conditions optimization and complex equipments design. The increasing of ultrasonic machining use, in various technologies is due to the expanding need of a wide range materials and high quality manufacture standards in many activity fields. This paper present a experimental study made in order to analyze the welded zone material structure and welding quality. The effects of aluminium ultrasonic welding parameters such as relative energy, machining time, amplitude and working force were compared through traction tests values and microstructural analysis. Microhardness tests were, also, made in five different points, two in the base material and three in the welded zone, on each welded aluminium sample. The aluminum welding experiments were made at the National Research and Development Institute for Welding and Material Testing (ISIM) Timişoara. The ultrasonic welding temperature is lower than the aluminium melting temperature, that's so our experiments reveal that the aluminium ultrasonic welding process doesn't determine the appearance of moulding structure. In the joint we have only crystalline grains deformation, phase transformation and aluminium diffusion.

Determination of Ultrasonic Welding Optimal Parameters for Thermoplastic Material of Manufacturing Products

2013 ◽  
Vol 64 (1) ◽  
Author(s):  
Rashiqah Rashli ◽  
Elmi Abu Bakar ◽  
Shahrul Kamaruddin
Keyword(s):  
Electronic Device ◽  
Low Cost ◽  
Near Field ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Field Configuration ◽  
Welding Parameters ◽  
Optimal Parameters ◽  
Thermoplastic Material

Ultrasonic welding had been widely used in various manufacturing industries such as aviation, medical, electronic device and many more. It offers a continued safe operation, faster and also low cost as it able to join weld part less than one second and also simple to maintain the tooling devices. Though ultrasonic welding brings a lot of advantages in assembly especially in thermoplastic material of manufacturing product, it also has a dominant problem to be deal with. The problem in ultrasonic welding is poor weld quality due to improper selection of ultrasonic welding parameters especially in near field configuration. Thus, an optimal combination of parameters is crucial in order to produce good quality weld assembly for this configuration. In this paper, ultrasonic welding process, ultrasonic weld joint defects and determination of optimal parameters for thermoplastic material had been discussed thoroughly. 

scholarly journals Influence of Welding Parameters On Grain Size, Haz and Degree of Dilution in 6063-t5 Alloy. Optimisation Through the Taguchi Method of the Gmaw Welding Process.

2022 ◽  
Author(s):  
Jose Luis Meseguer Valdenebro ◽  
Eusebio José Martínez Conesa ◽  
Antonio Portoles
Keyword(s):  
Grain Size ◽  
Taguchi Method ◽  
Heat Affected Zone ◽  
Welding Process ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Taguchi’S Method ◽  
Gmaw Welding ◽  
Made In

Abstract The aim of this work is to carry out the design of experiments that determine the influence of the welding parameters using Taguchi’s method on the grain size, HAZ, and the degree of dilution in 6063-T5 alloy. The welding process used is GMAW and the welding parameters are power, welding speed and bevel spacing. The study of the influence of the welding parameters on the measurements made in the welding (which are the size of heat affected zone, the degree of dilution, and the grain size) allows one to determine the quality of the joint . In addition, the welding parameter most influential in minimising the three measurements will be determined.

Micro Thin Film Sensor Embedding in Metals by Ultrasonic Welding for Production of Miniature Smart Tooling

2004 ◽  
Author(s):  
Xudong Cheng ◽  
Patrick Schwieso ◽  
Hongseok Choi ◽  
Arindom Datta ◽  
Xiaochun Li
Keyword(s):  
Thin Film ◽  
Thin Sheet ◽  
Welding Process ◽  
Weld Interface ◽  
Ultrasonic Welding ◽  
Film Sensor ◽  
Thin Film Sensor ◽  
Safety And Reliability ◽  
Thin Film Thermocouples ◽  
Nickel Strip

This work is to study micro thin film sensor embedding in metals for the production of miniature smart tooling. This technique promises to significantly improve the safety and reliability for manufacturing processes and reduce operation costs. One key concern of the current research is to investigate if sensor functionality can be maintained during and after embedding in metals by use of ultrasonic welding (USW), which could be hostile to micro thin film thermocouples (TFTCs) embedded near the welding interface. The welding workpieces, consisting of a nickel strip with embedded micro sensors and a copper thin sheet, were welded by USW process. Experimental results showed that TFTCs survived the ultrasonic welding process. The embedded TCFCs were also capable of measuring temperature in-situ near the weld interface during the embedding process.

Effects of Welding Parameters in Micro Friction Stir Lap Welding of Aluminum A1100

2013 ◽  
Vol 789 ◽  
pp. 356-359 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
A.A.D. Nugroho ◽  
D. Rahayu ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
...  
Keyword(s):  
Tilt Angle ◽  
Welding Process ◽  
Tool Material ◽  
Tensile Load ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Welding ◽  
Welding Processes

Technology of Friction Stir Welding (FSW) as a technique for joining metal is relatively new. In some cases on Aluminum joining, FSW gives better results compared with the Arc Welding processes, including the quality of welds and less distortion. FSW can even use milling machine or drilling machine, by replacing the tools and the appropriate accessories. The purpose of this study is to analyze the effect of process parameters onmicro Friction Stir Lap Weldingto the tensile load of welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. Tool shoulder diameter was 3 mm, while the diameter pin was 2 mm and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of spindle speed (2300, 2600, and 2900 rpm), variable oftooltilt angle(0, 1, 2 degree) and a variable ofFeed rate(50, 60, 70 mm/min). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was the tensile load. Analysis and optimization parameters between the micro FSLW parameters with the tensile load of welds, is used aResponse Surface Methods(RSM). From the result of experiment and analysis, it is shown that the important welding parameter in Micro Friction Stir Lap welding process is tilt angle.

Laser Transmission Welding of Thermoplastics—Part II: Experimental Model Validation

2007 ◽  
Vol 129 (5) ◽  
pp. 859-867 ◽  
Author(s):  
James D. Van de Ven ◽  
Arthur G. Erdman
Keyword(s):  
Polyvinyl Chloride ◽  
Welding Process ◽  
Weld Strength ◽  
Average Error ◽  
Welding Parameters ◽  
Laser Transmission Welding ◽  
Weld Width ◽  
Additional Information ◽  
Primary Model ◽  
Clamping Pressure

Two laser transmission welding experiments involving polyvinyl chloride are presented that aim to validate a previously presented welding model while helping to further understand the relationship between welding parameters and weld quality. While numerous previous research papers have presented the results of laser welding experiments, there exists minimal work validating models of the welding process. The first experiment explores the interaction of laser power and welding velocity while the second experiment explores the influence of clamping pressure. Using the weld width as the primary model output, the agreement between the welding experiments and the model have an average error of 5.6%. This finding strongly supports the validity of the model presented in Part I of this two paper set (Van de Ven and Erdman, 2007, ASME J. Manuf. Sci. Eng., 129, pp. 849–858). Additional information was gained regarding the operating window for laser transmission welding and the thermal decomposition of polyvinyl chloride. Clamping pressure was found to provide a small, but not statistically significant, influence on the visual appearance, weld width, and weld strength.

scholarly journals Application Features of Ultrasonic Welding

2018 ◽  
Vol 9 (1) ◽  
pp. 31-34
Author(s):  
Gyula Bagyinszki ◽  
Enikő Bitay
Keyword(s):  
Production Line ◽  
Weld Seam ◽  
Filler Metal ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Welding Parameters

Abstract The technological advantages of ultrasonic welding: (no requirement for filler metal; use of small electrical transient resistance contacts; ability to weld thin materials to thick materials) results in a helium-solid weld seam; the computer configuration of the welding parameters can easily be solved; clean and safe workflow (no sparks, flame or smoke); can be integrated into the production line. This article deals with some of the additional application features of this welding process.

scholarly journals Producing a Dissimilar Joint of Copper to Austenitic Stainless Steel by Ultrasonic Welding

2021 ◽  
Vol 4 (2) ◽  
pp. 109-112
Author(s):  
Schramkó Márton ◽  
Kovács Tünde Anna
Keyword(s):  
Stainless Steel ◽  
Sheet Thickness ◽  
Welding Process ◽  
Physical And Mechanical Properties ◽  
Test Sample ◽  
Tensile Tests ◽  
Ultrasonic Welding ◽  
Welding Parameters ◽  
Thin Sheets ◽  
Standard Size

Abstract There are several possibilities for establishing a cohesion joint between dissimilar metals. In the case of thin sheets, the ultrasonic welding process is suitable. This process can establish a cohesion joint rapidly, with a low heat input between the thin sheets. The authors have tried to determine the optimal ultrasonic welding parameters for copper and austenite stainless steel joining by using an experimental method of joining. Suitable results were obtained by welding tests due dissimilarities in the chemical, physical and mechanical properties of the copper and stainless steel. A standard size sheet thickness and test sample was used for the welding by different parameters. The parameters were refined based on the theoretical and practical knowledge during the experiments. The experimental welding was made by a Branson L20 type welder machine. The joint made by the different parameters was inspected by shearing-tensile tests (maximal force level).

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