Abstract
The effects of welding energy on the mechanical and microstructural characteristics of ultrasonic-welded pure copper plates were investigated. Complex dynamic recrystallization and grain growth occurred inside the weld zone during ultrasonic welding. At a low welding energy, a thin band of straight weld interfaces was observed and had an ultra-fine grain structure. With an increase in welding energy, the weld interface progressively changed from flat to sinusoidal, and eventually turned into a convoluted wavy pattern, bearing similarities to shear instabilities, as observed in fluid dynamics. The lap shear load of the joints initially increased and then remained stable as the welding energy increased. The tensile characteristics of the joints significantly depended on the development of plastic deformation at the interface. The influence of the microstructure on the hardness was also discussed.
Highlights
Copper and corresponding alloys have been widely utilized in battery assemblies in the battery electric vehicles (BEVs) industry, due to their merits, including the high electrical and thermal conductivities of both, and the subsequent favorable combination of strength and ductility [1]
Cu-Cu joints fabricated by ultrasonic welding (USW) was performed
The main conclusions deriving from this work are: joints fabricated by USW was performed
Summary
Copper and corresponding alloys have been widely utilized in battery assemblies in the battery electric vehicles (BEVs) industry, due to their merits, including the high electrical and thermal conductivities of both, and the subsequent favorable combination of strength and ductility [1]. A high demand exists for joining in battery pack manufacturing. A significant amount of heat is generated in the weld, leading to a rapid increment in the cell temperature. This will destroy the separator in the cell, causing an internal failure [4]. In order for such problems to be overcome, solid-state welding methods, such as friction stir welding (FSW) and ultrasonic welding (USW), have been regarded as alternative solutions for the joining of copper in battery pack manufacturing
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