Ultrasonic soldering as a method of assembly of products from dissimilar materials

2020 ◽  
Author(s):  
G.YU. Ivanov ◽  
A.D. Frolov
Keyword(s):  
Dissimilar Materials ◽  
Ultrasonic Soldering

The application of ultrasonic soldering when connecting dissimilar materials instead of traditional soldering is considered. Keywords ultrasonic soldering, cavitation, solder, ultrasonic systems. [email protected]

Analytical and High-Resolution EM Study of Crystalline Phases formed at Metal-Ceramic Interface

1990 ◽  
Vol 48 (2) ◽  
pp. 426-427
Author(s):  
N. Merk ◽  
A. P. Tomsia ◽  
G. Thomas
Keyword(s):  
Cross Section ◽  
Dissimilar Materials ◽  
Ceramic Materials ◽  
Electron Micrograph ◽  
Scanning Electron Micrograph ◽  
Structural Applications ◽  
Metal Ceramic ◽  
The Subject ◽  
Ceramic Compounds ◽  
Scanning Electron

A recent development of new ceramic materials for structural applications involves the joining of ceramic compounds to metals. Due to the wetting problem, an interlayer material (brazing alloy) is generally used to achieve the bonding. The nature of the interfaces between such dissimilar materials is the subject of intensive studies and is of utmost importance to obtain a controlled microstructure at the discontinuities to satisfy the demanding properties for engineering applications . The brazing alloy is generally ductile and hence, does not readily fracture. It must also wett the ceramic with similar thermal expansion coefficient to avoid large stresses at joints. In the present work we study mullite-molybdenum composites using a brazing alloy for the weldment.A scanning electron micrograph from the cross section of the joining sequence studied here is presented in Fig. 1.

Interfacial structures of dissimilar materials joined by capacitor-discharge welding

1994 ◽  
Vol 52 ◽  
pp. 534-535
Author(s):  
C. P. Doğan ◽  
R. D. Wilson ◽  
J. A. Hawk
Keyword(s):  
Rapid Solidification ◽  
Fusion Zone ◽  
Dissimilar Materials ◽  
Solidification Process ◽  
Weld Interface ◽  
Capacitor Discharge ◽  
Fine Grained ◽  
Iron Aluminum ◽  
Conductive Ceramics ◽  
Capacitor Discharge Welding

Capacitor Discharge Welding is a rapid solidification technique for joining conductive materials that results in a narrow fusion zone and almost no heat affected zone. As a result, the microstructures and properties of the bulk materials are essentially continuous across the weld interface. During the joining process, one of the materials to be joined acts as the anode and the other acts as the cathode. The anode and cathode are brought together with a concomitant discharge of a capacitor bank, creating an arc which melts the materials at the joining surfaces and welds them together (Fig. 1). As the electrodes impact, the arc is extinguished, and the molten interface cools at rates that can exceed 106 K/s. This process results in reduced porosity in the fusion zone, a fine-grained weldment, and a reduced tendency for hot cracking.At the U.S. Bureau of Mines, we are currently examining the possibilities of using capacitor discharge welding to join dissimilar metals, metals to intermetallics, and metals to conductive ceramics. In this particular study, we will examine the microstructural characteristics of iron-aluminum welds in detail, focussing our attention primarily on interfaces produced during the rapid solidification process.

Evaluation of Strength in Dissimilar Materials Joint

2018 ◽  
Vol 87 (1) ◽  
pp. 57-61
Author(s):  
Yukio MIYASHITA ◽  
Yoshiharu MUTOH
Keyword(s):  
Dissimilar Materials

Ultrasonic Torsion Welding of Aging Resistant Al/CFRP Joints - Concepts, Mechanical and Microstructural Properties

2017 ◽  
Vol 742 ◽  
pp. 395-400 ◽  
Author(s):  
Florian Staab ◽  
Frank Balle ◽  
Johannes Born
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Materials Science ◽  
Dissimilar Materials ◽  
Material Design ◽  
Ultrasonic Welding ◽  
Fatigue Properties ◽  
Aviation Industry ◽  
Efficient Design ◽  
Engineering Structures

Multi-material-design offers high potential for weight saving and optimization of engineering structures but inherits challenges as well, especially robust joining methods and long-term properties of hybrid structures. The application of joining techniques like ultrasonic welding allows a very efficient design of multi-material-components to enable further use of material specific advantages and are superior concerning mechanical properties.The Institute of Materials Science and Engineering of the University of Kaiserslautern (WKK) has a long-time experience on ultrasonic welding of dissimilar materials, for example different kinds of CFRP, light metals, steels or even glasses and ceramics. The mechanical properties are mostly optimized by using ideal process parameters, determined through statistical test planning methods.This gained knowledge is now to be transferred to application in aviation industry in cooperation with CTC GmbH and Airbus Operations GmbH. Therefore aircraft-related materials are joined by ultrasonic welding. The applied process parameters are recorded and analyzed in detail to be interlinked with the resulting mechanical properties of the hybrid joints. Aircraft derived multi-material demonstrators will be designed, manufactured and characterized with respect to their monotonic and fatigue properties as well as their resistance to aging.

Evaluation of the mechanical properties of Inconel 718 to SCM 440 dissimilar friction welding through real-time monitoring of the acoustic emission system

2021 ◽  
pp. 146442072199383
Author(s):  
Yu Sik Kong ◽  
Muralimohan Cheepu ◽  
Jin-Kyung Lee
Keyword(s):  
Acoustic Emission ◽  
Friction Welding ◽  
Inconel 718 ◽  
Low Voltage ◽  
Dissimilar Materials ◽  
Average Frequency ◽  
Very High Frequency ◽  
Cumulative Count ◽  
Emission System ◽  
Very High

Friction welding was chosen for its versatility in the joining of dissimilar materials with high quality. The aim of this study is to determine the optimal welding conditions for attaining quality joints by using online monitoring of acoustic emission system signals. During friction welding, the formation of cracks, defects, or any abnormalities in the joining process which have a detrimental effect on the joints quality was identified. The most widely used materials in the aerospace industry—Inconel 718 and molybdenum steel—were joined by friction welding. The precision of the joints, internal defects, and quality are major concerns for aerospace parts. The results of the present research determined the optimal welding conditions for high tensile strength by nondestructively inducing acoustic emission signals. During friction time and upset time periods, the typical waveforms and frequency spectrum of the acoustic emission signals were recorded, and their energy level, average frequency, cumulative count, and amplitude were analyzed. Both cumulative count and amplitude were found to be useful parameters for deriving the optimal welding conditions. In the initial stage of friction welding, a very high voltage of continuous form was generated with frequency characteristics of 0.44 MHz and 0.54 MHz. The signals generated during the upset stage had a low voltage, but a very high frequency of 1.56 MHz and 1.74 MHz with a burst-type signal. The amplitude of the signal generated for the optimally welded joints was about 100 dB at the friction time and about 45 dB at the upset time.

scholarly journals A design concept of active cooling for tailored forming workpieces during induction heating

2021 ◽  
Vol 15 (2) ◽  
pp. 177-186
Author(s):  
Caner-Veli Ince ◽  
Anna Chugreeva ◽  
Christoph Böhm ◽  
Fadi Aldakheel ◽  
Johanna Uhe ◽  
...  
Keyword(s):  
Dissimilar Materials ◽  
Heating Process ◽  
Algorithmic Approach ◽  
Cooling Strategy ◽  
Heating And Cooling ◽  
Temperature Constraint ◽  
Inhomogeneous Temperature ◽  
Specific Temperature ◽  
Tailored Forming

AbstractThe demand for lightweight construction is constantly increasing. One approach to meet this challenge is the development of hybrid components made of dissimilar materials. The use of the hybrid construction method for bulk components has a high potential for weight reduction and increased functionality. However, forming workpieces consisting of dissimilar materials requires specific temperature profiles for achieving sufficient formability. This paper deals with the development of a specific heating and cooling strategy to generate an inhomogeneous temperature distribution in hybrid workpieces. Firstly, the heating process boundaries with regard to temperature parameters required for a successful forming are experimentally defined. Secondly, a design based on the obtained cooling strategy is developed. Next a modelling embedded within an electro-thermal framework provides the basis for a numerical determination of admissible cooling rates to fulfil the temperature constraint. Here, the authors illustrate an algorithmic approach for the optimisation of cooling parameters towards an effective minimum, required for applicable forming processes of tailored forming.

scholarly journals Characterization of Soldering Alloy Type Bi-Ag-Ti and the Study of Ultrasonic Soldering of Silicon and Copper

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 624
Author(s):  
Roman Kolenak ◽  
Igor Kostolny ◽  
Jaromir Drapala ◽  
Paulina Babincova ◽  
Peter Gogola
Keyword(s):  
Eutectic Reaction ◽  
Research Work ◽  
Copper Substrate ◽  
Liquid Bismuth ◽  
Alloy Type ◽  
Average Shear Strength ◽  
Average Shear ◽  
The Matrix ◽  
Solder Microstructure ◽  
Ultrasonic Soldering

The aim of the research work was to characterize the soldering alloy type Bi-Ag-Ti and to study the direct soldering of silicon and copper. Bi11Ag1.5Ti solder has a broad melting interval. Its scope depends mainly on the content of silver and titanium. The solder begins to melt at the temperature of 262.5 ∘C and full melting is completed at 405 ∘C. The solder microstructure consists of a bismuth matrix with local eutectics. The silver crystals and titanium phases as BiTi2 and Bi9Ti8 are segregated in the matrix. The average tensile strength of the solder varies around 42 MPa. The bond with silicon is formed due to interaction of active titanium with the silicon surface at the formation of a reaction layer, composed of a new product, TiSi2. In the boundary of the Cu/solder an interaction between the liquid bismuth solder and the copper substrate occurs, supported by the eutectic reaction. The mutual solubility between the liquid bismuth solder is very limited, on both the Bi and the Cu side. The average shear strength in the case of a combined joint of Si/Cu fabricated with Bi11Ag1.5Ti solder is 43 MPa.

scholarly journals Challenges in the Forging of Steel-Aluminum Bearing Bushings

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 803
Author(s):  
Bernd-Arno Behrens ◽  
Johanna Uhe ◽  
Tom Petersen ◽  
Christian Klose ◽  
Susanne E. Thürer ◽  
...  
Keyword(s):  
Intermetallic Layer ◽  
Dissimilar Materials ◽  
Intermetallic Phases ◽  
Internal Diameter ◽  
External Diameter ◽  
Forming Process ◽  
High Deformation ◽  
Eds Analysis ◽  
Steel Aisi ◽  
Metallurgical Bond

The current study introduces a method for manufacturing steel–aluminum bearing bushings by compound forging. To study the process, cylindrical bimetal workpieces consisting of steel AISI 4820 (1.7147, 20MnCr5) in the internal diameter and aluminum 6082 (3.2315, AlSi1MgMn) in the external diameter were used. The forming of compounds consisting of dissimilar materials is challenging due to their different thermophysical and mechanical properties. The specific heating concept discussed in this article was developed in order to achieve sufficient formability for both materials simultaneously. By means of tailored heating, the bimetal workpieces were successfully formed to a bearing bushing geometry using two different strategies with different heating durations. A metallurgical bond without any forging defects, e.g., gaps and cracks, was observed in areas of high deformation. The steel–aluminum interface was subsequently examined by optical microscopy, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). It was found that the examined forming process, which utilized steel–aluminum workpieces having no metallurgical bond prior to forming, led to the formation of insular intermetallic phases along the joining zone with a maximum thickness of approximately 5–7 µm. The results of the EDS analysis indicated a prevailing FexAly phase in the resulting intermetallic layer.

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