About this Abstract |
Meeting |
2020 AWS Professional Program
|
Symposium
|
2020 AWS Professional Program
|
Presentation Title |
Modal Analysis of Ultrasonic Welding to Enable Multi-spot Dissimilar Material Joining |
Author(s) |
Hui Huang, Jian Chen, Yuan Li, Zhili Feng, Xin Sun |
On-Site Speaker (Planned) |
Hui Huang |
Abstract Scope |
Ultrasonic welding (USW) as a solid-state joining method can be used to join various alloys, steels and plastics, representing a unique welding tool for dissimilar materials joining which is critical to vehicle lightweighting. Nevertheless, dynamics involved in USW may cause bond failure and sheet damage in multiple spot welds. A fundamental understanding of global dynamics and constraint effect is necessary for the wide adoption of USW in manufacturing sectors. In this study, a modal analysis tool was developed based on the steady state dynamics and mechanical load derived from thermomechanical simulation of the USW process. Hot spot phenomenon was predicted by modal analysis and captured by an infrared camera during USW. It is revealed that, the occurrence of hot spots in ultrasonic welding is sensitive to overlap area of the two sheets as well as the sheet thickness. For multiple spot welds, the coupon length and weld spacing are two important factors that affect the welding reliability and joint quality. The model was validated by welding experiment of aluminum alloy, magnesium alloy and high strength steel through comparison of relative motion, joint strength as well as fracture location. |
Proceedings Inclusion? |
Definite: Other |