Experimental studies on optimization of process parameters and finite element analysis of temperature and stress distribution on joining of Al–Al and Al–Al2O3 using ultrasonic welding

Abstract

This study is carried out to optimize the process parameters like weld time, weld pressure, and amplitude of vibration to maximize the weld strength in Al–Al welding using Taguchi’s design of experiments methodology. Experiments are conducted using 0.3-mm thick pieces of aluminum, and the temperature generated at the weld interface and the weld strength for all the specimens are measured. Also, a finite element model is developed that is capable of predicting the interface temperature and stress distribution during welding. Further, a preliminary study on the joining of alumina to aluminum is also carried out, and the finite element models of temperature and stress distribution during welding are simulated. Results of experimental work and FEM studies are compared and found to be in good agreement.