An Analysis of Mechanical Properties for Ultrasonically Welded Multiple C1220-Al1050 Layers

Jisun Kim,Kwangsan Chun,Sungwook Kang,In-Ju Kim,Jaewoong Kim

doi:10.3390/app9194188

Abstract

This study analyzed the characteristics of aluminum and copper sheets under multi-layer ultrasonic welding, and observed the strength, fracture type, and interface of the weld zone according to location. In addition, an experimental plan was developed using the Taguchi method to optimize the quadruple lap ultrasonic welding process conditions of 0.4t aluminum and copper sheets, and the experiment was performed for each of 25 welding condition. For strength evaluation, the ultrasonic welding performance was evaluated by measuring the tensile strength as a composite material and the shear force at the weld interface through two types of tensile tests: simultaneous tensile and individual tensile. To identify the individual shear strengths of the multi-layer dissimilar ultrasonic welds, three types of tensile tests were performed for each specimen depending on the location of the welded, and as the distance from the horn increased, each of shear strength decreased while the difference in strength value increased. For quadruple lap welding of pure aluminum and copper sheets, the S/N (Signal to Noise Ratio) was the highest at 64.48 with a coarse-grain pattern and optimal welding conditions, and this was selected as the optimal condition. To evaluate the optimized welding condition, additional tests were conducted using the welding conditions that showed the maximum strength values and the welding conditions optimized using the Taguchi method through simple tests. A strength evaluation of the optimized weldment was performed, and for a simultaneous tensile test, it was found that the strength of the optimized weldment was improved by 45% compared to other cases.

Highlights

Ultrasonic welding is one of the representative welding technologies using plastic flow, with low electrical resistance as the oxide film and impurities are removed and welded through the diffusion of metal by vibration [1,2,3]. Ultrasonic welding makes it possible to weld nonferrous metals or dissimilar metals that are difficult to bond using conventional methods, and it is mainly used for thin foils, because its effect on metal is relatively small compared to other welding methods due to the very short welding time
Ultrasonic welding makes it easy to weld the same kind of metals or dissimilar metals which are difficult to weld using conventional methods; since the weld can be performed
The specific value examined in this study is the shear strength

Summary

Introduction

Ultrasonic welding is one of the representative welding technologies using plastic flow, with low electrical resistance as the oxide film and impurities are removed and welded through the diffusion of metal by vibration [1,2,3]. Ultrasonic welding makes it possible to weld nonferrous metals or dissimilar metals that are difficult to bond using conventional methods, and it is mainly used for thin foils, because its effect on metal is relatively small compared to other welding methods due to the very short welding time. Ultrasonic welding makes it easy to weld the same kind of metals or dissimilar metals which are difficult to weld using conventional methods; since the weld can be performed. Sci. 2019, 9, 4188 at a low temperature, it minimizes thermal damage due to low thermal expansion. It has been capturing attention as a bonding technology for high-performance, multi-functional parts, because it is an eco-friendly method that does not use solder [5]

Objectives

Methods

Conclusion