Research on the influence of parameters in the ultrasonic welding process of aluminum alloy Al 6061
Abstract: 259
| 
PDF: 137 
##plugins.themes.academic_pro.article.main##
Author
Keywords:
Aluminium
Finite element model
Li-Ion battery
Ultrasonic welding
Abstract
Thanks to its many advantages, ultrasonic metal welding (UMW) is often used as a popular method for welding aluminium electrodes in the production of lithium-ion battery for electric vehicles. The control of welding process parameters is essential for achieving superior joint quality. However, simulating and investigating the behavior of the weld material and the entire weld production process is a substantial difficulty due to the complex interactions between mechanical and thermal fields occurring during the welding process. The main objective of this research is to determine the essential factors that have a substantial influence on the result of the ultrasonic welding process. The results of this study show that the oscillation frequency plays an important role in both temperature variation and the width of the heat-affected zone. The higher oscillation frequency leads to faster temperature variation and larger heat-affected zone due to increased relative motion of the weld plates.
References
-
[1] Bansal and K. M. Kockelman, “Forecasting Americans’ Long-Term Adoption of Connected and Autonomous Vehicle Technologies”, Transportation Research. Part A, Policy and Practice, vol. 95, Elsevier BV, pp. 49–63, 2017, https://doi.org10.1016/j.tra.2016.10.013.
[2] Harman and J. Albers, “The Ultrasonic Welding Mechanism as Applied to Aluminum-and Gold-Wire Bonding in Microelectronics”, IEEE Transactions on Parts, Hybrids, and Packaging, vol. 13, no. 4, Institute of Electrical and Electronics Engineers (IEEE), pp. 406–412, 1977, https://doi.org10.1109/tphp.1977.1135225.
[3] Watanabe, H. Sakuyama, and A. Yanagisawa, “Ultrasonic Welding between Mild Steel Sheet and Al–Mg Alloy Sheet”, Journal of Materials Processing Technology, vol. 209, no. 15–16, Elsevier BV, pp. 5475–5480, 2009, https://doi.org10.1016/j.jmatprotec.2009.05.006.
[4] Y. Kong, R. C. Soar, and P. M. Dickens, “Characterisation of Aluminium Alloy 6061 for the Ultrasonic Consolidation Process”, Materials Science and Engineering: A, vol. 363, no. 1–2, Elsevier BV, Dec. 2003, pp. 99–106.
[5] Y. Kong, R. C. Soar, and P. M. Dickens, “A Model for Weld Strength in Ultrasonically Consolidated Components”, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, vol. 219, no. 1, SAGE Publications, pp. 83–91, 2005, https://doi.org10.1243/095440605x8315.
[6] Yang and Z. Wang. “Cyclic Deformation and Fracture Behavior of Al Alloy 6061 Under the Action of Positive Mean Stresses”, Metallurgical Transactions A, vol. 24, no. 9, Springer Science and Business Media LLC, pp. 2083–93, 1993.
[7] Zhao, H. Li, H. Choi, W. Cai, J. A. Abell, and X. Li, “Insertable Thin Film Thermocouples for in Situ Transient Temperature Monitoring in Ultrasonic Metal Welding of Battery Tabs”, Journal of Manufacturing Processes, vol. 15, no. 1, Elsevier BV, pp. 136–140, 2013, https://doi.org10.1016/j.jmapro.2012.10.002.
[8] Elangovan, S. Semeer, and K. Prakasan, “Temperature and Stress Distribution in Ultrasonic Metal Welding - An FEA-Based Study”, Journal of Material Processing Technology, vol. 209, pp. 1143–1150, 2009.
[9] Siddiq and E. Ghassemieh, “Theoretical and FE Analysis of Ultrasonic Welding of Aluminum Alloy 3003”, Journal of Manufacturing Science and Engineering, vol. 131, no. 4, ASME International, p. 041007, 2009, https://doi.org10.1115/1.3160583.
[10] Elangovan, S. Semeer, and K. Prakasan, “Temperature and Stress Distribution in Ultrasonic Metal Welding-An FEA-Based Study”, Journal of Materials Processing Technology, vol. 209, no. 3, Elsevier BV, pp. 1143–1150, 2009, https://doi.org10.1016/j.jmatprotec.2008.03.032.
[11] Jedrasiak, H. R. Shercliff, Y. C. Chen, L. Wang, P. Prangnell, and J. Robson, “Modeling of the Thermal Field in Dissimilar Alloy Ultrasonic Welding”, Journal of Materials Engineering and Performance, vol. 24, no. 2, Springer Science and Business Media LLC, pp. 799–807, 2015, https://doi.org10.1007/s11665-014-1342-8.
[12] Lee, E. Kannatey-Asibu, and W. Cai, “Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs”, Journal of Manufacturing Science and Engineering, vol. 135, no. 6, ASME International, 2013, https://doi.org10.1115/1.4025668.
[13] K. Chen and Y. S. Zhang. “Numerical Analysis of Temperature Distribution during Ultrasonic Welding Process for Dissimilar Automotive Alloys”, Science and Technology of Welding & Joining, vol. 20, no. 6, SAGE Publications, pp. 522–531, 2015, https://doi.org10.1179/1362171815y.0000000022.
[14] L. Chaboche, “A Review of Some Plasticity and Viscoplasticity Constitutive Theories”, International Journal of Plasticity, vol. 24, no. 10, Elsevier BV, pp. 1642–93, Oct. 2008, https://doi.org10.1016/j.ijplas.2008.03.009.
[15] L. Chaboche, “Viscoplastic constitutive equations for the description of cyclic and anisotropic behaviour of metals”, Acad. Polo. Sci., Sev. Sc. Et. Techn., vol. 25, pp. 39-48, 1977.
[16] Ohno and J. D. Wang. “Kinematic Hardening Rules with Critical State of Dynamic Recovery. Part I: Formulation and Features for Ratcheting Behaviour”, Int. J. Plasticity, vol. 9, pp. 373–390, 1993.
[17] Ohno and J. D. Wang, “Kinematic Hardening Rules with Critical State of Dynamic Recovery. Part II: Application to Experiments of Ratcheting Behaviour”, Int. J. Plasticity, vol. 9, pp. 391–403, 1993.
[18] S. Srivatsan, S. Sriram, and C. Daniels, “Influence of Temperature on Cyclic Stress Response and Fracture Behavior of Aluminum Alloy 6061”, Engineering Fracture Mechanics, vol. 56, no. 4, Elsevier BV, pp. 531–50, 1997.
[19] R. Johnson and W. Cook, “Fracture Characteristics of Three Metals Subjected to Various Strains, Strain Rates, Temperatures and Pressures”, Engineering Fracture Mechanics, vol. 21, no. 1, Elsevier BV, pp. 31–48, 1985, https://doi.org10.1016/0013-7944(85)90052-9.
[20] G. Kaufman, “Properties of Aluminum Alloys: Tensile, Creep, and Fatigue Data at High and Low Temperatures”, ASM, Metals Park, OH 44073-0002, USA, 1999.
[21] Langenecker, “Effects of Ultrasound on Deformation Characteristics of Metals”, IEEE Transactions on Sonics and Ultrasonics, vol. 13, no. 1, Institute of Electrical and Electronics Engineers (IEEE), pp. 1–8, 1966.
[22] Chen and Y. Zhang, “Mechanical Analysis of Ultrasonic Welding Considering Knurl Pattern of Sonotrode Tip”, Materials & Design, vol. 87, Elsevier BV, pp. 393–404, 2015.
[23] B. Zhang, X.J. Zhu, and L.J. Li, “A Study of Friction Behaviour in Ultrasonic Welding (Consolidation) of Aluminium”, AWS Conference: Session 7: Friction and Resistance Welding/Materials Bonding Processes, 2006.
[24] T. Watanabe, H. Itoh, A. Yanagisawa, and M. Hiraishi, “Ultrasonic welding of heat-treatable aluminium alloy A6061 sheet”, Welding International, vol. 23, no. 9, pp. 633-639, 2009.
Read more
##plugins.themes.academic_pro.article.sidebar##
Published
Sep 30, 2024
Download
How to Cite
Đinh Lê Cao Kỳ, Trương Thị Phương Hồng, Lê Phú Vinh, Lê Thể Truyền, and Hồ Thị Mỹ Nữ. “Research on the Influence of Parameters in the Ultrasonic Welding Process of Aluminum Alloy Al 6061”. The University of Danang - Journal of Science and Technology, vol. 22, no. 9A, Sept. 2024, pp. 26-34, https://jst-ud.vn/jst-ud/article/view/9177.
