Abstract
Electrical and automobile industries have high demands for an effective joining of dissimilar materials because of their enormous use. In the present research, numerical and experimental investigations have been conducted to study the effect of parameters of ultrasonic spot weld on metal joints for electronic components. Copper and brass alloy sheets have been welded using ultrasonic spot welding in the lap configuration. Regression analysis in combination with analysis of variance has been applied to formulate the models. Based on the optimum condition determined for the input parameters, mechanical and microstructural analysis is performed using tensile testing and SEM analysis, respectively. Finite-element modelling (FEM) simulation is conducted for the temperature near heat-affected zone (HAZ) and fusion zone (FZ). The results obtained from experiments are compared with the simulation results obtained from FEM modelling. Slight variations in tensile properties of the weldments that are free from defects have been observed with increase in welding time and frequency. A close agreement between the experimental and simulated values of FEM has been observed, which establishes the validity of reasonable accuracy of the model.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Kerans, W.H.: Welding handbook, 7th edn. Am. Weld. Soc., Miami (1982)
Chang, U.I., Frisch, J.: On optimization of some parameters in ultrasonic metal welding. Weld. J. 53(1), 24 (1974)
DeVries, E.: Mechanics and mechanism of ultrasonic metal welding. Ph.D. Dissertation, The Ohio State University (2004)
Satpathy, M.P., Bikash, R.M., Shailesh, D., Susanta, K.S.: Modeling and optimization of ultrasonic metal welding on dissimilar sheets using fuzzy based genetic algorithm approach. Eng. Sci. Technol. Int. J. (2015)
Watanabe, T., Sakuyama, H., Yanagisawa, A.: Ultrasonic welding between mild steel sheet and Al–Mg alloy sheet. J. Mater. Process. Technol. 34, 1107–1111 (2009)
Sun, Y.F., Xu, N., Fujii, H.: The microstructure and mechanicalproperties of friction stir welded Cu-30Zn brass alloys. Mater Sci. Eng. 589, 228–234 (2014)
Luo, J., Shanshan, L., Wei-Chen, Xiaoling, X.: Friction interface migration of copper alloy and carbon steel dissimilar metal joints in inertia radial friction welding. Mater. Manuf. Process. 31(3), 275–282 (2016)
Zhou, L., Li, Z.Y., Zhao, H.Y., Xie, Y., Huang, Y.X., Feng, J.C.: Microstructure and mechanical properties of Al/brass dissimilar metals TIG welding-brazing joint. Chin. J. Nonferrous Metals 25(9), 2389–2395 (2015)
Erdem, M.: Investigation of structure and mechanical properties of copper-brass plates joined by friction stir welding. Int. J. Adv. Manuf. Technol. 76(9–12), 1583–1592 (2015)
Matsuoka, S., Hisashi, I.: Direct welding of different metals used ultrasonic vibration. J. Mater. Process. Technol. 209(2), 954–960 (2009)
Elangovan, S., Prakasan, K., Jaiganesh, V.: Optimization of ultrasonic welding parameters for copper to brass joints using design of experiments. Int. J. Adv. Manuf. Technol. 51, 163–171 (2010)
Cheng, X., Xiaochun, L.: Investigation of heat generation in ultrasonic metal welding using micro sensor arrays. J. Micromech. Micro-Eng. 17(2), 273 (2007)
Gencsoy, H.T., Admas, J.A., Shigeo, S.: On some fundamental problems in ultrasonic welding of dissimilar metals. Weld. J. 4, 145s–153s (1967)
Chen, Y.-C., Bakavos, D., Gholinia, A., Prangnell, P.B.: HAZ development and accelerated post-weld natural ageing in ultrasonic spot welding aluminium 6111-T4 automotive sheet. Acta Mater. 60(6), 2816–2828 (2012)
Akbari, M.S., Niknejad, S.T.: An investigation on microstructure and mechanical properties of Nd:YAG laser beam weld of copper beryllium alloy. Metall. Mater. Trans. A 40, 1469–1478 (2009)
Prager, M., Dralle, C.W., Gaffoglio, C.J., Wold, K.G., Goldstein, S.H., Waterbury, W.V.: In: Kearns, W.H. (ed.) AWS Welding Handbook Metals and Their Weldability, vol. 4, pp. 278, 7th edn. AWS, New York (1982)
Canyurt, O.E., Kim, H.R., Lee, K.Y.: Estimation of laser hybrid welded joint strength by using genetic algorithm approach. Mech. Mater. 40, 825–831 (2008)
Cochran, W.G., Cox, G.M.: Lattice designs. In: Experimental Designs, pp. 396–438. Wiley, New York (1992)
Myers, R.H., Montgomery, D.C., Anderson-Cook, C.M.: Response Surface Methodology: Process and Product Optimization Using Designed Experiments. Wiley (2016)
De Vries, E.: Mechanics and mechanisms of ultrasonic metal welding. Ph.D. Dissertation, The Ohio State University, (2004)
Siddiq, A., Elaheh, G.: Thermo-mechanical analyses of ultrasonic welding process using thermal and acoustic softening effects. Mech. Mater. 40(12), 982–1000 (2008)
Zhang, C.Q., Robson, J.D., Prangnell, P.B.: Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to titanium alloy TiAl6V4. J. Mater. Process. Technol. 231, 382–388 (2016)
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Mohan Raj, N. et al. (2020). Experimental and Numerical Procedure for Studying Effect of Ultrasonic Spot Weld Parameters on Metal Joints for Electronic Components. In: Singh, I., Bajpai, P., Panwar, K. (eds) Trends in Manufacturing Processes. Lecture Notes on Multidisciplinary Industrial Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-32-9099-0_2
Download citation
DOI: https://doi.org/10.1007/978-981-32-9099-0_2
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-32-9098-3
Online ISBN: 978-981-32-9099-0
eBook Packages: EngineeringEngineering (R0)