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.

Recommendations for Submerged Arc Spiral Welding With Optimized CTOD Properties

2018 ◽  
Author(s):  
Martin Liebeherr ◽  
Özlem E. Güngör ◽  
Nuria Sanchez ◽  
Hervé Luccioni ◽  
Nenad Ilic
Keyword(s):  
Weld Metal ◽  
Base Material ◽  
Welding Process ◽  
Experimental Program ◽  
Welding Parameters ◽  
Pipe Production ◽  
Filler Wire ◽  
Crack Tip Opening Displacement ◽  
Wide Range ◽  
Submerged Arc

Many pipe mills may not be familiar with a Crack Tip Opening Displacement (CTOD) requirement on the pipe seam weld, nor will they find easily relevant information in open literature. Influencing — and certainly not independent — factors are: welding parameters, base material and consumable selection. Out of these, the welding parameters such as heat input and cooling rate cannot be varied over a wide range during the pipe production, which means that the leverage is rather limited at the given welding process. The properties of the heat affected zone will be mainly affected by the base material, while the properties of the weld metal will be affected by both, base material and filler wire selection. In particular with respect to the weld metal properties it will be difficult to obtain general quantitative information. For example, a welding consumable supplier will readily provide the properties of the filler wires but would be unable to predict the changes caused by the dilution from any base material in the weld pool and specific welding procedures that may have been used. To support the pipe mills in the selection of the consumables for submerged arc welding, an experimental program was launched with the aim to provide recommendations on how to optimize CTOD toughness of the spiral weld seam. For this, a large number of welds were produced on 20 mm thick X70 coil samples, with eight different filler wire combinations, using a 2-wire (tandem) set-up for both the inside and outside weld. Welding parameters were kept constant. The welding program was applied to two different X70 steels to determine a potential influence of the micro-alloying elements, particularly Nb. The results show clearly that a careful consumable selection is required for obtaining acceptable CTOD toughness in the weld metal. Ni-Mo and Ti-B additions to the weld metal are found to be beneficial with both steel concepts. Mo addition alone both to the ID and OD welds was clearly not a suitable selection.

Mechanical Behaviour of Al-Li Alloy Joints by Different Friction Stir Welding Parameters

2014 ◽  
Vol 1051 ◽  
pp. 799-807 ◽  
Author(s):  
Dan Dan Zhang ◽  
Wen Qing Qu ◽  
Qun Bo Lv ◽  
Yang Yang Liu ◽  
Wei Yan Li ◽  
...  
Keyword(s):  
Ultimate Strength ◽  
Base Material ◽  
Welding Process ◽  
Fatigue Properties ◽  
Welding Parameters ◽  
Fatigue Lifetime ◽  
Friction Stir ◽  
The Relationship ◽  
Microstructure And Mechanical Property ◽  
Made In

In this study, the Al-Li alloy plates were friction stir welded (FSW) at different welding parameters, and the effect of welding parameters on the hardness, tensile and fatigue properties of the butted and lapped FSWed joints were investigated. The experimental results showed that the ultimate strength and elongation of butted joints decreased as the heat input increasing, and the maximum ultimate strength of the joints was equivalent to 83% that of the base material. By comparison of the heat inputs during welding process at different parameter combinations, the relationship between the microstructure and mechanical property of FSWed joints was established. For the overlapped welds made in 2mm thick plates of Al-Li-S4 and 2099 alloys, the hooking defect was a typical and inevitable defect appearing on the TMAZ of both advancing and retreating sides, which would adversely damage the mechanical properties of overlapped joints. Furthermore, the length of pin significantly affected the tensile property of overlapped joints, when the length of pin varies from 2.8mm to 2.5mm, the ultimate strength increased 14% to 20%. In addition, the fatigue lifetime of overlapped joints was lower than that of butted joints and base metal.

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.

Mechanical Properties and Corrosion Resistance of Friction Stir Welded Dissimilar Aluminum Alloys 2219 to 5083

2015 ◽  
Vol 813-814 ◽  
pp. 203-207
Author(s):  
M. Koilraj ◽  
A. Sathesh Kumar ◽  
D.L. Belgin Paul ◽  
S.R. Koteswara Rao
Keyword(s):  
Base Material ◽  
Welding Process ◽  
Weld Nugget ◽  
Welding Parameters ◽  
General Corrosion ◽  
Test Results ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Shoulder Diameter ◽  
Mechanical Properties And Corrosion

In this paper, 6 mm thickness dissimilar aluminium alloys of 5083 (H321) and 2219 (O) butt joints were fabricated successfully by friction stir welding process. The quality joints were obtained for the welding parameters of 35 mm/min and 650 rpm with the shoulder diameter to pin diameter ratio as 3. Macrostructure study shows that the interface between the weld nugget and TMAZ is smooth and clear with a flow arm extending towards the top surface of the weld in the 2219 side. The boundary on the 5083 side between the weld nugget and the TMAZ was irregular. The obtained joint efficiency is around 92.57% based on the UTS of the softer material (AA2219). The tensile test results showed that the specimens failed in the heat affected zone of the softer base material 2219. The hardness values in the stirred zone are higher than the softer base material of alloy 2219. The friction stir welded dissimilar joint 2219-5083 exhibited better general corrosion characteristics than the 2219-2219 weld and 2219 base material.

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).

scholarly journals Determining the Degree of Admixing Rate of the Base Material and the Melting Efficiency in Single-Bead Surface Welds Using Different Methods, Including New Approaches

Materials ◽  
2019 ◽  
Vol 12 (9) ◽  
pp. 1479
Author(s):  
Matija Zorc ◽  
Aleš Nagode ◽  
Borut Kosec ◽  
Borut Zorc
Keyword(s):  
Cross Sections ◽  
Base Material ◽  
Welding Process ◽  
Precise Determination ◽  
Welding Parameters ◽  
Negative Consequences ◽  
Surface Areas ◽  
Bead Surface ◽  
Single Bead ◽  
Surface Welding

The precise determination of the admixing rate of the base material for certain welding parameters is very important because of the possible negative consequences. As such, it is the basis for corrections in welding technology. In the article, experimental and theoretical determinations of the admixing rate in single-bead surface welds that were arc welded onto S355 steel with different alloyed-steel-coated electrodes are discussed. The admixing rate was experimentally estimated from the ratio of the surface areas of metallographic cross-sections, from the ratios of the height and from chemical analyses of different regions of the surface weld, while it was theoretically estimated from the characteristics of the welding process and material constants. One of the key characteristics of the welding process is the melting efficiency, which can be estimated by means of different equations and from knowledge of the heat balance of the welding process. Both the average melting efficiency of the surface welding on the medium-thick S355 steel plate and the average admixing rate of the S355 steel into the surface welds have the same value, i.e., approximately 30%. New equations for estimating the melting efficiency of the arc welding with a coated electrode were developed on the basis of the results.

Seam properties of ultrasonic welded multilayered textile materials

2016 ◽  
Vol 46 (5) ◽  
pp. 1193-1211 ◽  
Author(s):  
Simona Jevšnik ◽  
Selin Hanife Eryürük ◽  
Fatma Kalaoğlu ◽  
Burçak Karagüzel Kayaoğlu ◽  
Petra Komarkova ◽  
...  
Keyword(s):  
Statistical Analysis ◽  
Bond Strength ◽  
Water Permeability ◽  
Bonding Strength ◽  
Water Resistance ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Welding Parameters ◽  
Textile Materials ◽  
Different Types

This study examined the effects of ultrasonic welding parameters on bond strength, seam thickness and seam stiffness, as well as water permeability. For study purpose, two types of four-layered fabrics with same compositions and different areal densities suitable for inner part of sport shoes were used. Two different types of seams, lapped and superimposed, were applied for ultrasonic welding and also compared by traditional seam applied by shoe manufacturer. The morphology of different type of seams was also analyzed to observe the influence of welding parameters on the layers during the ultrasonic welding process. Bonding strength was found to depend on the seam type and composition of the joined fabric layers. It was confirmed by the shoe manufacturer that all the produced welded seams provided the requested minimum bond strength to be suitable for the use of the shoes. The traditional seams applied by the shoe manufacturer were thicker but had lower stiffness in comparison to all welded seams. It was also found out that ultrasonic welding damaged the membrane, which was confirmed by no water resistance of welded seams. Statistical analysis showed that ultrasonic welding parameters, such as welding frequency and velocity, influence the bond strength, thickness, and bending stiffness of welded seams, but the obtained results were statistically insignificant.

scholarly journals Friction stir welding of new electronic packaging materials SiCp/Al composite with T-joint

2018 ◽  
Vol 38 (3) ◽  
pp. 352-359
Author(s):  
Zeng Gao ◽  
Jianguang Feng ◽  
Huanyu Yang ◽  
Jukka Pakkanen ◽  
Jitai Niu
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Welding Process ◽  
Experimental Results ◽  
Homogeneous Distribution ◽  
Welding Parameters ◽  
Matrix Composites ◽  
Friction Stir ◽  
Lower Temperature ◽  
Gas Tightness

Using friction stir welding, the electronic container box and lid made from aluminium matrix composites with reinforcement of SiC particle (15 vol% SiCp/Al-MMCs) was welded successfully with T-joint. The temperature distribution of box during the process, mechanical property and microstructure of the joint as well as gas tightness of welded box was investigated. The experimental results indicated that the satisfactory T-joint can be obtained under appropriate friction stir welding parameters. During the welding process, the bottom center, which was used to place the electronic component, reached a quite lower temperature of 100°C. That can ensure safety of components in the box. After the welding process, the microstructure in stir zone was better than in base material due to the refining and homogeneous distribution of the SiC particles. The experimental results showed that the electronic container box after friction stir welding had gas tightness. The He-leakage rate was under 10-8 Pa•m3/s.

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