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Abstract

Nowadays the automotive industry mostly prefers innovative solid-state welding technologies that would enable to welding of lightweight and high-performance materials. In this work, 3105-H18 Aluminium alloy (Al) and pure Copper (Cu) specimens with 0.5 mm thickness have been ultrasonically welded in a dissimilar (Al-Cu) manner. Optimization of process parameters of ultrasonic welding has been carried out through full factorial method, three levels of variables considered for this experimental studies namely, weld pressure, amplitude, and time, also each variable interaction with welding strength has been studied. Additionally, micro-hardness and microstructure investigation in welded joints has been studied. The result shows that the weld strength greatly influenced weld amplitude at a medium and higher level of weld pressure. The interface micro-hardness of the welded joint has lower compared to the base metal.
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Authors and Affiliations

A. Mohan Kumar
1
ORCID: ORCID
R. Rajasekar
1
ORCID: ORCID
V. Karthik
2
ORCID: ORCID
S. Kheawhom
3
ORCID: ORCID

  1. School of Building and Mechanical Sciences, Kongu Engineering College, Erode, Tamilnadu, India - 6380602
  2. NIT, Tiruchirappalli, Department of Metallurgical and Materials Engineering, Tamilnadu, India – 620015
  3. Chulalongkorn University, Faculty of Engineering, Department of Chemical Engineering, Bangkok, Thailand – 10330
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Abstract

This article presents the main stages and challenges in modelling and designing of modern ultrasonic welding and cutting systems. First, the key components of such a system, such as an ultrasonic stack (con- sisting of a high power ultrasonic transducer and a sonotrode) and a digitally controlled ultrasonic power supply with precise control of the output power, have been considered. Next, a concept of measurement system for verification and validation of mathematical models of ultrasonic stacks and its components has been presented. Finally, a method of ultrasonic stack e-diagnosis based on ultrasonic transducer electrical impedance measurement during welding and cutting process has been described
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Authors and Affiliations

Andrzej Milewski
Piotr Kluk
Witold Kardyś
Paweł Kogut

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