Simulation of Ultrasonic Welding of Al-Cu Dissimilar Metals for Battery Joining

Subject Areas : optimization and simulation

Reza Abdi Behnagh ¹ , Peyman Esmaeilzadeh ² , Mohsen Agha Mohammad Pour ³

1 - Faculty of Mechanical Engineering, Urmia University of Technology, Urmia, Iran
2 - Faculty of Mechanical Engineering, Urmia University of Technology, Iran
3 - Faculty of Mechanical Engineering, Urmia University of Technology, Iran

Received: 2019-08-16 Accepted : 2020-02-05 Published : 2020-06-01

Keywords:

References:

[1]     Ying Li, L. E., Flores, R. D., Elizabeth Trillo, A., and McClure, J. C., Intercalation Vortices and Related Microstructural Features in The Friction-Stir Welding of Dissimilar Metals, Materials Research Innovations, Vol. 2, No. 3, 1998, pp. 150–163. Doi: 10.1007/s100190050078.

[2]     Watanabe, T., Sakuyama, H., and Yanagisawa, A., Ultrasonic Welding Between Mild Steel Sheet and Al–Mg Alloy Sheet, Journal of Materials Processing Technology, Vol. 209, No. 15–16, 2009 pp. 5475–5480. Doi: 10.1016/j.jmatprotec.2009.05.006.

[3]     Shin, H. S., Leon De, M., Parametric Study in Similar Ultrasonic Spot Welding of A5052-H32 Alloy Sheets, J. Mater. Process. Technol., Vol. 224, 2015, pp. 222–232. Doi: 10.1016/j.jmatprotec.2015.05.013.

[4]     Yang, J. W., Cao, B., He, X. C., and Luo, H. S., Microstructure Evolution and Mechanical Properties of Cu–Al Joints by Ultrasonic Welding, Science and Technology of Welding and Joining, Vol. 19, No. 6, 2014, pp. 500–504. Doi: 10.1179/1362171814Y.0000000218.

[5]     Zhao, Y. Y., Li, D., and Zhang, Y. S., Effect of Welding Energy On Interface Zone of Al–Cu Ultrasonic Welded Joint, Science and Technology of Welding and Joining, Vol. 18, No. 4, 2013, pp. 354–360. Doi: 10.1179/1362171813Y.0000000114.

[6]     Elangovan, S., Experimental and Theoretical Investigations On Temperature Distribution at The Joint Interface for Copper Joints Using Ultrasonic Welding, Manufacturing Review, Vol. 1, 2014, pp. 18. Doi: 10.1051/mfreview/2014017.

[7]     Kim, T. H., Yum, J., Hu, S. J., Spicer, J. P., and Abell, J. A., Process Robustness of Single Lap Ultrasonic Welding of Thin, Dissimilar Materials, CIRP Annals, Vol. 60, No. 1, 2011, pp. 17–20, Doi: 10.1016/j.cirp.2011.03.016.

[8]     Zhang, C. Y., Chen, D. L., and Luo, A. A., Joining 5754 Automotive Aluminium Alloy 2-mm-Thick Sheets Using Ultrasonic Spot Welding, Welding Journal, Vol. 93, 2014 pp. 131–138.

[9]     De Vries, E., Mechanics and Mechanisms of Ultrasonic Metal Welding, Ph.D. Dissertation, The Ohio State University, pp. 253, 2004.

[10]  Siddiq, A., Ghassemieh, E., Thermomechanical Analyses of Ultrasonic Welding Process Using Thermal and Acoustic Softening Effects, Mechanics of Materials, Vol. 40, No. 12, 2008, pp. 982–1000. Doi: 10.1016/j.mechmat.2008.06.004.

[11]  Elangovan, S., Prakasan, K., and Jaiganesh, V., Optimization of Ultrasonic Welding Parameters for Copper to Copper Joints Using Design of Experiments, The International Journal of Advanced Manufacturing Technology, Vol. 51, No. 1–4, 2010, pp. 163–171. Doi: 10.1007/s00170-010-2627-1.

[12]  Jedrasiak, P., Shercliff, H. R., Chen, Y. C., Wang, L., Prangnell, P., and Robson, J., Modelling of the Thermal Field in Dissimilar Alloy Ultrasonic Welding, Journal of Materials Engineering and Performance, Vol. 24, No. 2, 2014, pp. 799–807. Doi: 10.1007/s11665-014-1342-8.

[13]  Elangovan, S., Semeer, S., and Prakasan, K., Temperature and Stress Distribution in Ultrasonic Metal Welding—An FEA-Based Study, Journal of Materials Processing Technology, Vol. 209, No. 3, 2009, pp. 1143–1150.

[14]  Chen, K. K., Zhang, Y. S., Numerical Analysis of Temperature Distribution During Ultrasonic Welding Process for Dissimilar Automotive Alloys, Science and Technology of Welding and Joining, Vol. 20, No. 6, 2015, pp. 522–531. Doi: 10.1179/1362171815Y.0000000022.

[15]  Konchakova, N., Balle, F., Barth, F. J., Mueller, R., Eifler, D., and Steinmann, P., Finite Element Analysis of an Inelastic Interface in Ultrasonic Welded Metal/Fibre-Reinforced Polymer Joints, Computational Materials Science, Vol. 50, No. 1, 2010, pp. 184–190. Doi: 10.1016/j.commatsci.2010.07.024.

[16]  Lee, D., Kannatey-Asibu, E., and Cai, W., Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs, Journal of Manufacturing Science and Engineering, Vol. 135, No. 6, 2013, pp. 061011. Doi: 10.1115/1.4025668.

[17]  Zhang, C., Li, L., A Coupled Thermal-Mechanical Analysis of Ultrasonic Bonding Mechanism, Metallurgical and Materials Transactions, Vol. 40, No. 2, 2009, pp. 196–207, Doi: 10.1007/s11663-008-9224-9.

[18]  Kim, T. H., Yum, J., Hu, S. J., Spice,r J. P., and Abell, J. A., Process Robustness of Single Lap Ultrasonic Welding of Thin, Dissimilar Materials, CIRP Annals - Manufacturing Technology, Vol. 60, No. 1, 2011, pp. 17–2. Doi: 10.1016/j.cirp.2011.03.016.

[19]  Lee, D., Kannatey-Asibu, E., and Cai, W., Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs, Journal of Manufacturing Science and Engineering, Vol. 135, No. 6, 2013, p. 061011. Doi: 10.1115/1.4025668.