Ultrasonic Welding of Aluminum and Silicon Wafer

2006 ◽  
Vol 505-507 ◽  
pp. 841-846
Author(s):  
Kuen Ming Shu ◽  
Hung Rung Shih
Keyword(s):  
Experimental Study ◽  
Silicon Wafer ◽  
Ultrasonic Welding ◽  
Vacuum Deposition ◽  
Aluminum Wire ◽  
Welding Condition ◽  
Microstructure Observation ◽  
Deposit Surface ◽  
Welding Processes ◽  
Welding Force

There are several types of welding method to join metal and ceramic. This paper gives a description of an experimental study of the ultrasonic welding of aluminum wire and silicon wafer under the conditions of the frequency of ultrasonic vibration f = 38000Hz, the applied duration T=0.2-1.5 sec, and the welding force Ps =40-140 gf. In this study, vacuum deposition was first applied to deposit surface modification aluminum on silicon wafer, then ultrasonic welding processes were investigated to join aluminum wire and modified silicon wafer. Based on the results of the microstructure observation and tensile test, it is believed that the joining ability can be improved under optimum welding condition.

Advances in joining technologies for the innovation of 21st century lightweight aluminium-CFRP hybrid structures

2022 ◽  
pp. 095440892110730
Author(s):  
Renangi Sandeep ◽  
Arivazhagan Natarajan
Keyword(s):  
Shear Strength ◽  
Laser Welding ◽  
Heat Input ◽  
Mechanical Performance ◽  
Current Knowledge ◽  
Ultrasonic Welding ◽  
Hybrid Structures ◽  
Joint Shear Strength ◽  
Hybrid Joints ◽  
Welding Processes

In the twenty-first century, the application of carbon fiber reinforced polymer (CFRP) materials in the vehicle industry are growing rapidly due to lightweight, high specific strength, and elasticity. In the automobile and aerospace industries, CFRP needs to be joined with metals to build complete structures. The demand for hybrid structures has prompted research into the combination of CFRP and metals in manufacturing. Aluminium and CFRP structures combine the mechanical properties of aluminium with the superior physical and chemical properties of CFRP. However, joining dissimilar materials is often challenging to achieve. Various joining technologies are developed to produce hybrid joints of CFRP, and aluminium alloys include conventional adhesives, mechanical and thermal joining technologies. In this review article, an extensive review was carried out on the thermal joining technologies include laser welding, friction-based welding technologies, ultrasonic welding, and induction welding processes. The article primarily focused on the current knowledge and process development of these technologies in fabricating dissimilar aluminium and CFRP structures. Besides, according to Industry 4.0 requirements, additive manufacturing-based techniques to fabricate hybrid structures are presented. Finally, this article also addressed the various improvements for the future development of these joining technologies. Ultrasonic welding yields the maximum shear strength among the various hybrid joining technologies due to lower heat input. On the other hand, laser welding produces higher heat input, which deteriorates the mechanical performance of the hybrid joints. Surface pretreatments on material surfaces prior to joining showed a significant effect on joint shear strength. Surface modification using anodizing is considered an optimal method to improve wettability, increasing mechanical interlocking phenomena.

Ultrasonic Welding of Soft Polymer and Metal: A Preliminary Study

2019 ◽  
Author(s):  
Yuquan Meng ◽  
Dingyu Peng ◽  
Qasim Nazir ◽  
Gowtham Kuntumalla ◽  
Manjunath C. Rajagopal ◽  
...  
Keyword(s):  
Heat Exchangers ◽  
Waste Heat ◽  
Ultrasonic Welding ◽  
Operating Conditions ◽  
Innovative Products ◽  
Soft Polymer ◽  
Heat Exchanges ◽  
Future Work ◽  
Welding Processes ◽  
Soft Polymers

Abstract Joining soft polymers and metals is receiving increasing attention in both industry and academia to enable the manufacturing of innovative products. One motivation arises from the production of next-generation heat exchanges, the structure of which is primarily composed of polymers and metals. Waste heat coming from low temperature exhaust gas stream is significant in industries in the U.S. However, traditional heat exchangers that are available to recover heat in the presence of small temperature difference are large and costly, restricting the wide application of such heat exchangers. To address this challenge, a hybrid materials design is proposed to achieve a balance between thermal conductivity and mechanical strength. High quality requirement induced by the changing operating conditions necessitates a strong bonding between polymers and copper. In this research, the possibility of using ultrasonic welding, which is conventionally employed to join dissimilar or similar metal layers, is explored. Preliminary results from welding experiments and tensile shear tests reveal that two bonding modes exist in the welding of PET and copper. Furthermore, analysis of power signals collected during welding shows that one can potentially monitor and optimize welding processes using monitoring signals. It is concluded from this study that ultrasonic welding has excellent potential in joining soft polymers and metals. Future work is also discussed on the process improvement and mechanism investigation.

Effect of Relative Motion between Weld Tool and Work Piece on Microstructure of Ultrasonically Welded Joint

2014 ◽  
Vol 783-786 ◽  
pp. 1782-1787 ◽  
Author(s):  
Tomohiro Sasaki ◽  
Yusuke Hosokawa
Keyword(s):  
Relative Motion ◽  
Pure Aluminum ◽  
Weld Interface ◽  
Ultrasonic Welding ◽  
Work Piece ◽  
Plastic Deformation Zone ◽  
Weld Microstructure ◽  
Aluminum Sheets ◽  
Third Stage ◽  
Welding Processes

Ultrasonic welding is conducted using pure aluminum sheets to investigate effect of the transitional welding processes comprised of three transitional stages on the formation of the weld microstructure. In the first stage of ultrasonic welding, the relative motion mainly occurred between the workpieces, and a partially bonded region was observed in the weld interface. In the second stage, the relative motion at the weld interface was suppressed by the formation of the partially bonded region, while relative motion between the weld tool and the workpiece in contact with the weld tool. The relative motion at the weld tool/workpiece caused weld temperature rise with a penetration the weld tool edge. In the third stage, a plastic deformation zone generated by the relative motion at the weld tool/workpiece spread into the lower side of weld part as the welding time increased. It is proposed that the formation of weld microstructure in ultrasonic welding is attributed to the thermo-mechanically effect of the relative motion of the weld tool and workpiece.

scholarly journals Experimental study on scan imaging of silicon wafer by laser-induced photocarrier radiometry

2015 ◽  
Vol 64 (8) ◽  
pp. 087804
Author(s):  
Liu Jun-Yan ◽  
Song Peng ◽  
Qin Lei ◽  
Wang Fei ◽  
Wang Yang
Keyword(s):  
Experimental Study ◽  
Silicon Wafer ◽  
Photocarrier Radiometry

Experimental and Analytical Strength Characterization of an Ultrasonic Welded Lap Shear Joint

2001 ◽  
Author(s):  
Samuel Ibekwe ◽  
Patrick F. Mensah ◽  
Ghanashyam Joshi ◽  
Guoqiang Li ◽  
Michael Stubblefield
Keyword(s):  
Experimental Study ◽  
Composite Materials ◽  
Statistical Difference ◽  
Ultrasonic Welding ◽  
Lap Shear ◽  
Shear Joint ◽  
Strength Characterization

Abstract An experimental study on ultrasonic welding of thermoplastic, which is a prelude to study how the technology can be adapted to join composite materials, was conducted. Three sets of specimen were studied to investigate the influence of energy guide on the bonded specimen. No major statistical difference between the ‘energy guides’ of the tested thermoplastic Celuka™ coupons were noted. Failure of the welded specimen was by shear at the interface. A 75% drop in strength for the bonded material was observed.

Experimental study on radiation characteristics of aluminum wire-array Z-pinches

2013 ◽  
Vol 25 (7) ◽  
pp. 1731-1735
Author(s):  
蒋树庆 Jiang Shuqing ◽  
潘英俊 Pan Yingjun ◽  
甯家敏 Ning Jiamin ◽  
夏广新 Xia Guangxin ◽  
秦义 Qin Yi ◽  
...  
Keyword(s):  
Experimental Study ◽  
Wire Array ◽  
Aluminum Wire ◽  
Radiation Characteristics

Analysis of Weld Formation in Multilayer Ultrasonic Metal Welding Using High-Speed Images

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
S. Shawn Lee ◽  
Tae Hyung Kim ◽  
S. Jack Hu ◽  
Wayne W. Cai ◽  
Jeffrey A. Abell
Keyword(s):  
High Speed ◽  
Lateral Displacement ◽  
Welding Process ◽  
Lithium Ion ◽  
Ultrasonic Welding ◽  
Fusion Welding ◽  
Tool Geometry ◽  
Weld Quality ◽  
Weld Formation ◽  
Welding Processes

One of the major challenges in manufacturing automotive lithium-ion batteries and battery packs is to achieve consistent weld quality in joining multiple layers of dissimilar materials. While most fusion welding processes face difficulties in such joining, ultrasonic welding stands out as the ideal method. However, inconsistency of weld quality still exists because of limited knowledge on the weld formation through the multiple interfaces. This study aims to establish real-time phenomenological observation on the multilayer ultrasonic welding process by analyzing the vibration behavior of metal layers. Such behavior is characterized by a direct measurement of the lateral displacement of each metal layer using high-speed images. Two different weld tools are used in order to investigate the effect of tool geometry on the weld formation mechanism and the overall joint quality. A series of microscopies and bond density measurements is carried out to validate the observations and hypotheses of those phenomena in multilayer ultrasonic welding. The results of this study enhance the understanding of the ultrasonic welding process of multiple metal sheets and provide insights for optimum tool design to improve the quality of multilayer joints.

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