Ultrasonic Welding Simulations of Multiple, Thin and Dissimilar Metals for Battery Joining

2012 ◽  
Author(s):  
Dongkyun Lee ◽  
Elijah Kannatey-Asibu ◽  
Wayne Cai
Keyword(s):  
Automotive Industry ◽  
Semiconductor Industry ◽  
Computational Cost ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Ultrasonic Welding ◽  
Welding Quality ◽  
Dissimilar Metal ◽  
Simulation Procedure ◽  
Finite Element Procedure

Ultrasonic welding is a solid-state bond created using ultrasonic energy. It has been used in the semiconductor industry for several decades, and more recently, in the automotive industry such as for battery welding. Even though there existed several numerical simulations on ultrasonic welding, the models were too simplistic, in both theory and welding configuration, to present the multiple sheet, dissimilar metal ultrasonic welding. In this study, theories and a finite element procedure for the ultrasonic welding process are developed. The procedure invokes both Abaqus/Standard and Abaqus/Explicit to simulate the mechanical-thermal coupled phenomena over the entire weld duration with moderate computational cost. The procedure is verified and used to simulate selected specific cases involving multiple sheets and dissimilar materials, i.e., copper and aluminum. The simulation procedure demonstrates its capability to predict welding energy and temperature distribution of the workpieces, towards the goal of improving welding quality.

Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
Dongkyun Lee ◽  
Elijah Kannatey-Asibu ◽  
Wayne Cai
Keyword(s):  
Lithium Ion Battery ◽  
Automotive Industry ◽  
Semiconductor Industry ◽  
Computational Cost ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Lithium Ion ◽  
Ultrasonic Welding ◽  
Simulation Procedure ◽  
Thermal Phenomena

Ultrasonic welding is a solid-state bond created using ultrasonic energy. It has been used in the semiconductor industry for several decades, and more recently, in the automotive industry such as for lithium-ion battery welding. Although there existed numerical simulations for ultrasonic welding, the models were limited to two-layer and like materials stackups. In this study, finite element theories are introduced and simulation procedure is established for multiple sheets and dissimilar metal ultrasonic welding. The procedures require both abaqus/Standard and abaqus/Explicit to simulate the coupled mechanical-thermal phenomena over the entire weld duration with moderate computational cost. The procedure is verified and used to simulate selected specific cases involving multiple sheets and dissimilar materials, i.e., copper and aluminum. The simulation procedure demonstrates its capability to predict welding energy, distortion, and temperature distribution of the workpieces. Case studies of ultrasonic welding simulations for multiple layers of lithium-ion battery tabs are presented. The prediction leads to several innovative ultrasonic welding process designs for improved welding quality.

New Joining Techniques for the Production of the Electrical Components in the Automotive Industry

2018 ◽  
Vol 1146 ◽  
pp. 98-105 ◽  
Author(s):  
Radu Cojocaru ◽  
Cristian Ciucă ◽  
Lia Nicoleta Boţilă ◽  
Victor Verbiţchi ◽  
Ion Aurel Perianu
Keyword(s):  
Friction Stir Welding ◽  
Production Process ◽  
Automotive Industry ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Butt Welding ◽  
Friction Stir ◽  
Preliminary Results ◽  
Friction Stir Welding Process ◽  
Electrical Components

In the paper are presented some preliminary results regarding the possibilities of using of the friction stir welding process (FSW) and FSW assisted with TIG (FSW – TIG) welding for joining of the electrical components in the automotive industry. Couples of dissimilar materials approached in experiments were Aluminium EN AW 1200 and Copper Cu99, with thicknesses in conformity with real cases in the production process. The results obtained for butt welding an overlap welding of different thicknesses of materials (aluminium thickness s1 = 2mm and copper thickness s2 = 5mm) are presented. There are some general conclusions regarding the possibilities of joining the two materials under the specified conditions.

scholarly journals Dissimilar metal joining by ultrasonic welding

2021 ◽  
Vol 66 (2) ◽  
pp. 75-82
Author(s):  
Tünde Kovácsa ◽  
Annamária Vladárb ◽  
Peter Pinkec ◽  
Hassanen Jaberd
Keyword(s):  
Solid State ◽  
Welding Process ◽  
Physical And Mechanical Properties ◽  
Ultrasonic Welding ◽  
Fusion Welding ◽  
Advantages And Disadvantages ◽  
Dissimilar Metal ◽  
Simple Technology ◽  
High Level ◽  
Metal Welding

The dissimilar metal welding always challenges. The different alloys have different physical and mechanical properties. In the case of the electronic component of the car, it needs to establish a joint between dissimilar metals. The useful metals are for this application are copper and aluminium. Even that has good conductivity, corrosion resistance and formability. By fusion welding technologies these thin metal workpiece joining is not a simple technology. To use a solid state welding technology can be a suitable solution to establish a cohesion joint in case of this task. It well-known much suitable technologies, even that all of them has advantages and disadvantages. The choice of solid-state technology is the ultrasonic welding process. In the case of this process, we use pressure and high-frequency vibration for welding. Besides this process, the friction and vibration generated heat is lower than the metal melting temperature. The base of this technology is the ultrasound-assisted high-level formability. The optimization of this dissimilar joining technology parameters needs many pre-welding and testing process. In this work, we wanted to introduce this empirical optimization process.

General Aspects Concerning Possibilities of Joining by Friction Stir Welding for some of Couples of Materials Usable in the Automotive Industry

2019 ◽  
Vol 1153 ◽  
pp. 27-35 ◽  
Author(s):  
Radu Cojocaru ◽  
Lia Nicoleta Boţilă ◽  
Cristian Ciucă ◽  
Bogdan Radu ◽  
Victor Verbiţchi ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Automotive Industry ◽  
Ferrous Metal ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Industrial Applications ◽  
Friction Stir ◽  
Metal Materials ◽  
Materials Used ◽  
General Aspects

In recent years, due to its extraordinary qualities, friction stir welding process FSW has found its utility in more and more industrial applications in fields such as: aerospace, aeronautics, naval, automotive and railway. The paper summarizes several achievements in the FSW joining of couples of similar and dissimilar materials used in the automotive industry. There are presented aspects regarding the welding of ferrous metal materials (DD13), couples of non-ferrous metallic materials (Al Cu range) and steels with aluminum. The behavior of FSW of material couples in terms of analysis of microstructural improvements and mechanical characteristics is analyzed. The preliminary results obtained have shown that the FSW process can be successfully applied to the joining of the approached material couples, but with the use of optimized welding tools and technologies.

Metodología para el desarrollo de trayectorias en la aplicación por el proceso de soldadura GMAW en un robot industrial

2019 ◽  
pp. 1-4
Author(s):  
Josué Rafael Sánchez-Lerma ◽  
Luis Armando Torres-Rico ◽  
Héctor Huerta-Gámez ◽  
Ismael Ruiz-López
Keyword(s):  
Mechanical Properties ◽  
Automotive Industry ◽  
Industrial Robot ◽  
Welding Process ◽  
High Strength ◽  
Test Material ◽  
Advantages And Disadvantages ◽  
Application Characteristics ◽  
Joining Process ◽  
Gmaw Welding

This paper proposes the development of the methodology to be carried out for the metal joining process through the GMAW welding process in the Fanuc LR Mate 200iD industrial robot. The parameters or properties were considered for the application to be as efficient as possible, such parameters as speed of application, characteristics of the filler material, gas to be used as welding protection. The GMAW welding process can be applied semiautomatically using a hand gun, in which the electrode is fed by a coil, or an automatic form that includes automated equipment or robots. The advantages and disadvantages of the GMAW welding process applied in a manual and automated way were commented. The mechanical properties of the materials to which said welding can be applied were investigated; The materials with which this type of welding can be worked are the high strength materials, which are used in the automotive industry, for the forming of sheet metal. To know the properties of the material, destructive tests were carried out on the test material to be used, as well as the mechanical properties of the welding.

Ultrasonic Torsion Welding of Aging Resistant Al/CFRP Joints - Concepts, Mechanical and Microstructural Properties

2017 ◽  
Vol 742 ◽  
pp. 395-400 ◽  
Author(s):  
Florian Staab ◽  
Frank Balle ◽  
Johannes Born
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Materials Science ◽  
Dissimilar Materials ◽  
Material Design ◽  
Ultrasonic Welding ◽  
Fatigue Properties ◽  
Aviation Industry ◽  
Efficient Design ◽  
Engineering Structures

Multi-material-design offers high potential for weight saving and optimization of engineering structures but inherits challenges as well, especially robust joining methods and long-term properties of hybrid structures. The application of joining techniques like ultrasonic welding allows a very efficient design of multi-material-components to enable further use of material specific advantages and are superior concerning mechanical properties.The Institute of Materials Science and Engineering of the University of Kaiserslautern (WKK) has a long-time experience on ultrasonic welding of dissimilar materials, for example different kinds of CFRP, light metals, steels or even glasses and ceramics. The mechanical properties are mostly optimized by using ideal process parameters, determined through statistical test planning methods.This gained knowledge is now to be transferred to application in aviation industry in cooperation with CTC GmbH and Airbus Operations GmbH. Therefore aircraft-related materials are joined by ultrasonic welding. The applied process parameters are recorded and analyzed in detail to be interlinked with the resulting mechanical properties of the hybrid joints. Aircraft derived multi-material demonstrators will be designed, manufactured and characterized with respect to their monotonic and fatigue properties as well as their resistance to aging.

scholarly journals Static ultrasonic welding of carbon fibre unidirectional thermoplastic materials and the influence of heat generation and heat transfer

2021 ◽  
pp. 002199832097681
Author(s):  
F Köhler ◽  
IF Villegas ◽  
C Dransfeld ◽  
A Herrmann
Keyword(s):  
Cross Sections ◽  
Weld Line ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Thermoplastic Composites ◽  
Squeeze Flow ◽  
Anisotropic Flow ◽  
Lap Shear ◽  
Anisotropic Thermal Conductivity ◽  
Edge Defects

Ultrasonic welding is a promising technology to join fibre-reinforced thermoplastic composites. While current studies are mostly limited to fabric materials the applicability to unidirectional materials, as found in aerospace structures, would offer opportunities for joining primary aircraft structures. However, due to the highly anisotropic flow of a molten unidirectional ply undesired squeeze flow phenomena can occur at the edges of the weld overlap. This paper investigates how the fibre orientation in the plies adjacent to the weld line influences the welding process and the appearance of edge defects. Ultrasonic welding experiments with different layups and energy director configurations were carried out while monitoring temperatures at different locations inside and outside the weld overlap. The joints were characterized by single lap shear tests, analysis of corresponding fracture surfaces and microscopic cross-sections. Results showed that the anisotropic flow and the anisotropic thermal conductivity of the plies adjacent to the weld line have a distinct effect on the appearance and location of edge defects. By using energy directors that cover only part of the weld overlap area a new approach was developed to mitigate edge defects caused by the highly directional properties of the unidirectional plies.

Brittle Fracture Analysis of a Dissimilar Metal Weld

2013 ◽  
Author(s):  
A. Blouin ◽  
S. Chapuliot ◽  
S. Marie ◽  
J. M. Bergheau ◽  
C. Niclaeys
Keyword(s):  
Brittle Fracture ◽  
Weld Joint ◽  
Threshold Stress ◽  
Base Alloy ◽  
Welding Process ◽  
Loading Conditions ◽  
Brittle To Ductile Transition ◽  
Dissimilar Metal ◽  
Dissimilar Metal Weld ◽  
Metal Weld

One important part of the integrity demonstration of large ferritic components is based on the demonstration that they could never undergo brittle fracture. Connections between a ferritic component and an austenitic piping (Dissimilar Metal Weld — DMW) have to respect these rules, in particular the Heat Affected Zone (HAZ) created by the welding process and which encounters a brittle-to-ductile transition. Within that frame, the case considered in this article is a Ni base alloy narrow gap weld joint between a ferritic pipe (A533 steel) and an austenitic pipe (316L stainless steel). The aim of the present study is to show that in the same loading conditions, the weld joint is less sensitive to the brittle fracture than the surrounding ferritic part of the component. That is to say that the demonstration should be focused on the ferritic base metal which is the weakest material. The bases of this study rely on a stress-based criterion developed by Chapuliot et al., using a threshold stress (σth) below which the cleavage cannot occur. This threshold stress can be used to define the brittle crack occurrence probability, which means it is possible to determine the highest loading conditions without any brittle fracture risk.

Experimental Investigations on Aluminium Ultrasonic Welding Parameters

2014 ◽  
Vol 657 ◽  
pp. 306-310
Author(s):  
Lăcrămioara Apetrei ◽  
Vasile Rață ◽  
Ruxandra Rață ◽  
Elena Raluca Bulai
Keyword(s):  
Microstructural Analysis ◽  
Base Material ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Experimental Investigations ◽  
Welding Parameters ◽  
Material Structure ◽  
Welding Temperature ◽  
Wide Range ◽  
Made In

Research evolution timely tendencies, in the nonconventional technologies field, are: manufacture conditions optimization and complex equipments design. The increasing of ultrasonic machining use, in various technologies is due to the expanding need of a wide range materials and high quality manufacture standards in many activity fields. This paper present a experimental study made in order to analyze the welded zone material structure and welding quality. The effects of aluminium ultrasonic welding parameters such as relative energy, machining time, amplitude and working force were compared through traction tests values and microstructural analysis. Microhardness tests were, also, made in five different points, two in the base material and three in the welded zone, on each welded aluminium sample. The aluminum welding experiments were made at the National Research and Development Institute for Welding and Material Testing (ISIM) Timişoara. The ultrasonic welding temperature is lower than the aluminium melting temperature, that's so our experiments reveal that the aluminium ultrasonic welding process doesn't determine the appearance of moulding structure. In the joint we have only crystalline grains deformation, phase transformation and aluminium diffusion.

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