Application of Ultrasonic Metal Welding for Joining Dissimilar ......Ultrasonic spot metal welding...

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www.uni-kl.de/WKKProf. Dr. D. Eifler

Application of Ultrasonic Metal Welding for Joining Dissimilar Materials

Frank BalleInstitute of Materials Science and Engineering (WKK)University of Kaiserslautern (Germany)


University of Manchester (Latest 2 – Nov. 2011)– F. Balle: Application of Ultrasonic Metal Welding for Joining Dissimilar Materials

Institute of Materials Science and EngineeringProf. Dr. D. Eifler

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Joining similar and dissimilar materials by ultrasonic welding

[Telsonic]

[Schunk]Ultrasonic weldingof metals

Ultrasonic weldingof polymers

[WKK]




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Kinematics of ultrasonic welding

US metal-US polymer-welding

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Ultrasonic metal welding, main principle

1

234

56

FUS

u

1 Ultrasonic generator2 Electric converter3 Booster

4 Sonotrode5 Joining partners6 Anvil

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Variants of ultrasonic metal welding, schematic

Spot welding Torsion welding Roll-seam welding

FS

FS

FS

uS

uS

uS

Oscillationdirection

Welding Force

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Important parameters of ultrasonic metal welding

F

u

Oscillationamplitude

Weldingforce

Weldingenergy

Time [s]

Gen

erat

or p

ower

[W]

Materials properties

Topography

Geometry

d2

d1

[µm]

Temperature50

Sonotrode

200

150

100

°C




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Ultrasonic Welding ofAluminum Wires

www.uni-kl.de/WKKwww.uni-kl.de/WKK

Prof. Dr. D. Eifler



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Motivation to substitute Cu-wires – Weight and Price

0,1

1

10

100

1,0E-01 1,0E+00 1,0E+01 1,0E+02 1,0E+03 1,0E+04 1,0E+05

Specific price [€/kg]0.1 1 10 102 103 104 105

0.1

Ag

Au

Ti

Fe

Al

1

10

100

El. c

ondu

ctiv

ity

/ Den

sity

[S

m²/k

g]

Cu AlDensity [kg/m³] 8.9 2.7Electricalconductivity [106 S/m]

58 37

El. conductivity / Density - /[106 S m²/kg]

6.5 13.7

Spec. Price[$/kg], 23.11.2011

7.40 2.07

Cu

[Balle et. al.; TMS 2010]

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Ultrasonic welding systems for wire materials at WKK

Wire to wire joints Wire to connector joints




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Realized Al-wire to Al-wire – joints (52 mm ²)

Sonotrode

Anvil

Cross section A-A

A

ASingle

filament

Polygonisation of thewires, but no fusion!

[Eifler et. al.; Weld. andCutt., 59, (2007), p. 550-554]




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Ultrasonic Welding of Aluminum Sheets to

Aluminum-Foam-Sandwich (AFS)

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Spot Welding5x5 mm2,

Sheet Metal X5CrNi1810

Roll Seam Welding3x30 mm2

Sheet Metal NiCo2917

Torsion Welding 18 mm,

Sheet Metal Al99,5 hh

Realized geometries for Metal/AFS-joints

AFS

Weld spot

AFS

Seam

Sheet Metal AFS

Weld ring

Sheet Metal

Sheet Metal

[Eifler et. al.; Adv. Eng. Mat., 9, (2006), p. 816-820)]

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Ultrasonic Welding of Aluminum Sheets to Carbon Fiber Reinforced Polymers (CFRP)

www.uni-kl.de/WKK

[F. Balle: PhD Thesis, University of Kaiserslautern, 2009, in German]www.uni-kl.de/WKK

Prof. Dr. D. Eifler



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Ultrasonic spot metal welding system for hybrid joints

Measurement unit

Process control unit

Spot weldingsystem

Sonotrode10 x 10 mm²

Clamping device

CFRP Sheet30 x 70 x 2 mm³

Metal Sheet25 x 70 x 1 mm³

[F. Balle: PhD Thesis, University of Kaiserslautern, 2009, in German]




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Influence of different process parameters for AA5754/CF-PA66 – joints

[Balle et. al.; Adv. Eng. Mat., 11 (2009)]




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Influence on weld strength by surface pre-treatment of the Al-surface

As rolled (R)

Ra = 0.3 µmRt = 1.7 µm

100 nm

Acid pickled (AP)

Ra = 0.3 µmRt = 1.2 µm

100 nm

(έ = 0.2 × 10-3 1/s)

AA5754(R)/CF-PA66

έ = 0,2 × 10-3 1/sAA5754(AP)/CF-PA66 έ = 0,2 × 10-3 1/s

[Balle et. al.; Proc. Eng. Vol10, 2011, p. 433-438]

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Cross section A-A

Model of the joining zone and selected micrographs (SEM)

Sonotrode tip

Aluminium

A

A

Aluminium

PA66C-fibres

CFRPwww.uni-kl.de/WKK

[Balle et. al.; Proc. Eng. Vol10, 2011, p. 433-438]




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AA1050-H14/CF-PA66

AA5754-H22/CF-PA66

AA2024-T6/CF-PA66

Fracture energy of ultrasonically welded Al/CFRP-joints

[Balle et. al.; ECAA 2011]




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Selected hybrid joints, realized at WKK

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Ultrasonic Torsion Weldingof Metal/Glass-Joints

Ultrasonic Roll-Seam Weldingof Metal/Ceramics-Joints




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Summary of selected welds

Al/BMG

Metal/Ceramics

Metal/GlassMetal/CFRP

CFRPFoams

Al-wireswww.uni-kl.de/WKK

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Many thanks to:

S. Huxhold, B. Straß, J. Magin, Dr. C. Born, Dr. M. Gutensohn, Dr. G. Wagner,

German Research Foundation (DFG) for the financial support,

State Research Center (CM)2

for my personal support.www.uni-kl.de/WKK

Prof. Dr. D. Eifler

Contact & further details:

University of Kaiserslautern, GermanyInstitute of Materials Science and Engineering (WKK)

Dr. Frank BalleE-Mail: [email protected]

www.uni-kl.de/WKK

Application of Ultrasonic Metal Welding for Joining Dissimilar ......Ultrasonic spot metal welding...

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