Ultrasonic Welding of Metal Sheets - CRC Press 2021
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Authored by
Susanta Kumar Sahoo,
Mantra Prasad Satpathy
First edition published 2021
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742
and by CRC Press
2 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
© 2021 Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, LLC
Contents
Preface.......................................................................................................................ix
About the Authors......................................................................................................xi
Chapter 1 Introduction...........................................................................................1
1.1 Fundamentals of Welding...........................................................1
1.2 Fusion Welding Techniques and Issues......................................2
1.3 Solid-State Welding Techniques and Issues...............................4
1.4 Necessity of Dissimilar Joints in Engineering
Structures....................................................................................5
1.5 Ultrasonic Spot Welding............................................................9
1.6 Brief Description of Ultrasonic Spot
Welding Equipment.................................................................. 11
1.6.1 Lateral Drive Spot Welding System............................ 11
1.6.2 Wedge-Reed Spot Welding System............................. 12
1.6.3 Other Ultrasonic Vibration-Assisted
Welding Processes....................................................... 13
1.7 Selected Illustrative Ultrasonic Spot
Welding Applications............................................................... 15
References...........................................................................................20
Chapter 2 Fundamentals of Ultrasonic Spot Welding.........................................23
2.1 Overview of the Ultrasonic Metal Welding Process................23
2.2 Weldable Materials and Their Geometries...............................25
2.3 Key Issues in the Ultrasonic Spot Welding Process.................28
2.3.1 Ultrasonic Welding System Component Design.........29
2.3.2 Heat Generation During the USW Process................. 31
2.3.3 Intermetallic Compound Evolution
During USW................................................................34
2.3.4 Acoustic Softening Effects on Weld Strength.............36
2.4 Pros and Cons of the USW Process......................................... 37
2.4.1 Advantages of the USW Process.................................38
2.4.2 Limitations of the USW Process.................................38
References........................................................................................... 39
Chapter 3 Tool and Fixture Design for Ultrasonic Spot Welding
of Dissimilar Metal Sheets.................................................................. 43
3.1 Theoretical Aspects of Tool and Fixture Design...................... 43
3.2 Application of Numerical Techniques for Tool
and Fixture Design...................................................................49
Chapter 4 Ultrasonic Spot Welding Configuration and Process
Parameter Selection.............................................................................81
4.1 Weld Coupon Configuration.....................................................81
4.2 Process Parameter Selection.....................................................83
4.2.1 Frequency of Vibration................................................84
4.2.2 Weld Pressure/Clamping Pressure/Static Load...........84
4.2.3 Vibrational Amplitude................................................84
4.2.4 Weld Time, Energy, and Power...................................85
4.3 Performance Measures in the USW Process............................86
4.3.1 Tensile Shear Load (TS)/Failure Load/Lap
Shear Failure Load......................................................86
4.3.2 T-Peel Failure Load (TP).............................................87
4.3.3 Strength Reduction Ratio (SRR).................................88
4.3.4 Stress Intensity Factor (SIF)........................................89
4.3.5 Joint Efficiency (JE)....................................................89
4.3.6 Total Failure Energy/Fracture Energy (TFE).............89
4.3.7 U-Tensile Load (UT)...................................................90
4.3.8 Fatigue Load/Strength.................................................91
4.3.9 Weld Area (WA)..........................................................91
4.3.10 Interface Temperature (T)...........................................92
4.3.11 Micro-Hardness...........................................................93
4.3.12 Electrical/Joint Resistance..........................................93
References...........................................................................................95
Chapter 5 Ultrasonic Spot Welding of Dissimilar Metal Sheets.........................97
5.1 Ultrasonic Spot Welding of Aluminum to Copper...................97
5.2 Ultrasonic Spot Welding of Aluminum
to Magnesium Alloys..............................................................107
5.3 Ultrasonic Spot Welding of Nickel to Al/Cu Alloys..............120
5.4 Ultrasonic Spot Welding of Aluminum to Steel Alloys.........130
5.5 Ultrasonic Spot Welding of Aluminum to Titanium Alloys........141
5.6 Ultrasonic Spot Welding of Aluminum to Brass Alloys........149
References.........................................................................................157
Chapter 6 Thermo-Mechanical Modeling in Ultrasonic Spot Welding
of Dissimilar Metal Sheets................................................................159
6.1 Theoretical Aspects of Thermo-Mechanical Modeling.........159
6.1.1 Structural Analysis....................................................161
6.1.1.1 Forces Related to the Dynamics
of the Top Workpiece.................................164
Chapter 7 Future Research Trends in Ultrasonic Spot Welding
of Dissimilar Metal Sheets................................................................217
7.1 Controlling Formation of Undesired
Intermetallic Compounds.......................................................217
7.2 Enhancing Weld Strength in Thicker Sheets..........................218
7.3 Corrosion Behavior Study of Weld Joints..............................218
7.4 Control of Tool Wear..............................................................218
7.5 Joining of Harder Materials...................................................219
7.6 Prospective Opportunities in Aerospace, Medical, Energy, and Automotive Sectors............................................219
Index.......................................................................................................................221
