Skip to main content

Advertisement

SpringerLink
Log in

Effect of Brass Interlayer Sheet on Microstructure and Joint Performance of Ultrasonic Spot-Welded Copper-Steel Joints

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Solid-state ultrasonic spot welding (USW) inevitably offers a potential solution for joining dissimilar metal combination like copper (Cu) and steel (SS). In this study, the USW has been performed on Cu (UNS C10100) and SS (AISI 304) with brass interlayer by varying various welding parameters, aiming to identify the interfacial reaction, changes in microstructure and weld strength. The highest tensile shear and T-peel failure loads of 1277 and 174 N are achieved at the optimum conditions like 68 µm of vibration amplitude, 0.42 MPa of weld pressure and 1 s of weld time. The fractured surface analysis of brass interlayer and AISI 304 stainless steel samples reveals the features like swirls, voids and intermetallic compounds (IMCs). These IMCs are composed of CuZn and FeZn composite-like structures with ~1.0 μm thickness. This confirms that the weld quality is specifically sensitive to the levels of input parameter combinations as well as the type of material present on the sonotrode side.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. P. Prangnell, F. Haddadi, and Y.C. Chen, Ultrasonic Spot Welding of Aluminium to Steel for Automotive Applications-Microstructure and Optimisation, Mater. Sci. Technol., 2011, 27(3), p 617–624

    Article  Google Scholar 

  2. I. Galvao, R.M. Leal, A. Loureiro, and D.M. Rodrigues, Material Flow in Heterogeneous Friction Stir Welding of Aluminium and Copper Thin Sheets, Sci. Technol. Weld. Join., 2013, 15(8), p 654–660

    Article  Google Scholar 

  3. P.B. Prangnell and D. Bakavos, Novel Approaches to Friction Spot Welding Thin Aluminium Automotive Sheet, Mater. Sci. Forum, 2010, 638, p 1237–1242

    Article  Google Scholar 

  4. V.K. Patel, S.D. Bhole, and D.L. Chen, Ultrasonic Spot Welded AZ31 Magnesium Alloy: Microstructure, Texture, and Lap Shear Strength, Mater. Sci. Eng. A, 2013, 569, p 78–85

    Article  Google Scholar 

  5. M. Annoni and M. Carboni, Ultrasonic Metal Welding of AA 6022–T4 Lap Joints: Part I—Technological Characterisation and Static Mechanical Behaviour, Sci. Technol. Weld. Join., 2011, 16(2), p 107–115

    Article  Google Scholar 

  6. S. Matsuoka and H. Imai, Direct Welding of Different Metals Used Ultrasonic Vibration, J. Mater. Process. Technol., 2009, 209(2), p 954–960

    Article  Google Scholar 

  7. I. Magnabosco, P. Ferro, F. Bonollo, and L. Arnberg, An Investigation of Fusion Zone Microstructures in Electron Beam Welding of Copper–Stainless Steel, Mater. Sci. Eng. A, 2006, 424(1), p 163–173

    Article  Google Scholar 

  8. T.A. Mai and A.C. Spowage, Characterisation of Dissimilar Joints in Laser Welding of Steel-Kovar, Copper-Steel and Copper-Aluminium, Mater. Sci. Eng. A, 2004, 374(1), p 224–233

    Article  Google Scholar 

  9. G. Phanikumar, S. Manjini, P. Dutta, K. Chattopadhyay, and J. Mazumder, Characterization of a Continuous CO2 Laser-Welded Fe-Cu Dissimilar Couple, Metall. Mater. Trans. A, 2005, 36(8), p 2137–2147

    Article  Google Scholar 

  10. A. Durgutlu, B. Gülenç, and F. Findik, Examination of Copper/Stainless Steel Joints Formed by Explosive Welding, Mater. Des., 2005, 26(6), p 497–507

    Article  Google Scholar 

  11. Y. Imani, M.K. Givi, and M. Guillot, Improving Friction Stir Welding Between Copper and 304L Stainless Steel, Adv. Mater. Res., 2012, 409, p 263–268

    Article  Google Scholar 

  12. S.G. Shiri, M. Nazarzadeh, M. Sharifitabar, and M.S. Afarani, Gas Tungsten Arc Welding of CP-Copper to 304 Stainless Steel Using Different Filler Materials, Trans. Nonferrous Met. Soc. China, 2012, 22(12), p 2937–2942

    Article  Google Scholar 

  13. J.D. Destefani, Properties and Selection: Nonferrous Alloys and Special-Purpose Materials, ASM Handb., 1992, 2, p 1770

    Google Scholar 

  14. Y.Y. Zhao, D. Li, and Y.S. Zhang, Effect of Welding Energy on Interface Zone of Al-Cu Ultrasonic Welded Joint, Sci. Technol. Weld. Join., 2013, 18(4), p 354–360

    Article  Google Scholar 

  15. R. Balasundaram, V.K. Patel, S.D. Bhole, and D.L. Chen, Effect of Zinc Interlayer on Ultrasonic Spot Welded Aluminum-to-Copper Joints, Mater. Sci. Eng. A, 2014, 607, p 277–286

    Article  Google Scholar 

  16. S.Q. Wang, V.K. Patel, S.D. Bhole, G.D. Wen, and D.L. Chen, Microstructure and Mechanical Properties of Ultrasonic Spot Welded Al/Ti Alloy Joints, Mater. Des., 2015, 78, p 33–41

    Article  Google Scholar 

  17. S.D. Beattie and J.R. Dahn, Comparison of Electrodeposited Copper-Zinc Alloys Prepared Individually and Combinatorially, J. Electrochem. Soc., 2003, 150(11), p C802–C806

    Article  Google Scholar 

  18. S.S. Lee, T.H. Kim, J.S. Hu, W.W. Cai, J.A. Abell, and J. Li, Characterization of Joint Quality in Ultrasonic Welding of Battery Tabs, J. Manuf. Sci. Eng., 2013, 135(2), p 1–13

    Google Scholar 

  19. C.Q. Zhang, J.D. Robson, and P.B. Prangnell, Dissimilar Ultrasonic Spot Welding of Aerospace Aluminum Alloy AA2139 to Titanium Alloy TiAl6V4, J. Mater. Process. Technol., 2016, 231, p 382–388

    Article  Google Scholar 

  20. C.Q. Zhang, J.D. Robson, O. Ciuca, and P.B. Prangnell, Microstructural Characterization and Mechanical Properties of High Power Ultrasonic Spot Welded Aluminum Alloy AA6111–TiAl6V4 Dissimilar Joints, Mater. Charact., 2014, 97, p 83–91

    Article  Google Scholar 

  21. V.K. Patel, S.D. Bhole, and D.L. Chen, Ultrasonic Spot Welding of Aluminum to High-Strength Low-Alloy Steel: Microstructure, Tensile and Fatigue Properties, Metall. Mater. Trans. A, 2014, 45(4), p 2055–2066

    Article  Google Scholar 

  22. F. Haddadi, Rapid Intermetallic Growth Under High Strain Rate Deformation During High Power Ultrasonic Spot Welding of Aluminium to Steel, Mater. Des., 2015, 66, p 459–472

    Article  Google Scholar 

  23. A. Macwan and D.L. Chen, Ultrasonic Spot Welding of Rare-Earth Containing ZEK100 Magnesium Alloy to 5754 Aluminum Alloy, Mater. Sci. Eng. A, 2016, 666, p 139–148

    Article  Google Scholar 

  24. M.-L. Zhu and F.-Z. Xuan, Effect of Microstructure on Strain Hardening and Strength Distributions Along a Cr–Ni–Mo–V Steel Welded Joint, Mater. Des., 2015, 65, p 707–715

    Article  Google Scholar 

  25. D.-Q. Wang, M.-L. Zhu, and F.-Z. Xuan, Correlation of Local Strain with Microstructures Around Fusion Zone of a Cr–Ni–Mo–V Steel Welded Joint, Mater. Sci. Eng. A, 2017, 685, p 205–212

    Article  Google Scholar 

  26. M.-L. Zhu, F.-Z. Xuan, and J. Chen, Influence of Microstructure and Microdefects on Long-Term Fatigue Behavior of a Cr–Mo–V Steel, Mater. Sci. Eng. A, 2012, 546, p 90–96

    Article  Google Scholar 

  27. M.G. Nicholas and C.F. Old, Liquid Metal Embrittlement, J. Mater. Sci., 1979, 14(1), p 1–18

    Article  Google Scholar 

  28. R.M. Bruscato, Liquid Metal Embrittlement of Austenitic Stainless Steel When Welded to Galvanized Steel, Weld. J. N. Y., 1992, 71, p 455–460

    Google Scholar 

  29. C.Y. Zhang, D.L. Chen, and A.A. Luo, Joining 5754 Automotive Aluminum Alloy 2-mm-Thick Sheets Using Ultrasonic Spot Welding, Weld. J., 2014, 93, p 131–138

    Google Scholar 

  30. F. Haddadi, D. Strong, and P.B. Prangnell, Effect of Zinc Coatings on Joint Properties and Interfacial Reactions in Aluminum to Steel Ultrasonic Spot Welding, JOM, 2012, 64(3), p 407–413

    Article  Google Scholar 

  31. L. Xu, L. Wang, Y.-C. Chen, J.D. Robson, and P.B. Prangnell, Effect of Interfacial Reaction on the Mechanical Performance of Steel to Aluminum Dissimilar Ultrasonic Spot Welds, Metall. Mater. Trans. A, 2016, 47(1), p 334–346

    Article  Google Scholar 

  32. C.P. Wang, X.J. Liu, M. Jiang, I. Ohnuma, R. Kainuma, and K. Ishida, Thermodynamic Database of the Phase Diagrams in Copper Base Alloy Systems, J. Phys. Chem. Solids, 2005, 66(2), p 256–260

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, ITS, IFHE, Hyderabad, 501203, India

    Mantra Prasad Satpathy

  2. Department of Mechanical Engineering, National Institute of Technology Rourkela, Odisha, 769008, India

    Abhishek Kumar & Susanta Kumar Sahoo

Authors
  1. Mantra Prasad Satpathy
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Abhishek Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Susanta Kumar Sahoo
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mantra Prasad Satpathy.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Satpathy, M.P., Kumar, A. & Sahoo, S.K. Effect of Brass Interlayer Sheet on Microstructure and Joint Performance of Ultrasonic Spot-Welded Copper-Steel Joints. J. of Materi Eng and Perform 26, 3254–3262 (2017). https://doi.org/10.1007/s11665-017-2772-x

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-017-2772-x

Keywords

Search

Navigation