Analysis of ultrasonic welding process of mild steel and 5052 aluminium alloy

Abstract

Ultrasonic welding of mild steel sheet (SPCC) and aluminium alloy sheet (A5052) was conducted using two different weld tips of a knurled tip (K-tip) and a curved shape tip without knurled edges (C-tip). Behaviours of the weld tip and the welded materials during the weld process were analysed using a high-speed camera observation and an image correlation. The C-tip welding shows a completely different displacement behaviour from the K-tip welding; a relative motion between the tool tip and A5052 in contact with the tip predominantly occurs in the C-tip in contrast to a relative motion between A5052 and SPCC observed in the K-tip. The joint strength using the C-tip was higher than that using the K-tip under the weld conditions in this study. It is demonstrated that the relative motion behaviour in the C-tip causes a macroscopic deformation of A5052 in the vibration direction. This phenomenon promotes growth of a bonded region, resulting in the increase of joint strength. It is surmised that Fe–Al intermetallic layer forms at the weld interface, and the joint strength consequently decreases for the longer weld time condition.