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Microstructure evolution and mechanical properties analysis in dissimilar ultrasonic metal welding of aluminum to copper

Yusefi, A ; Sharif University of Technology | 2024

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  1. Type of Document: Article
  2. DOI: 10.1016/j.jmrt.2024.04.037
  3. Publisher: 2024
  4. Abstract:
  5. Ultrasonic metal welding is a solid-state welding process being widely employed for joining the interconnections of lithium-ion batteries in hybrid and plug-in hybrid vehicles. Examining the microstructure of the joint is of crucial importance to evaluate the performance. This analysis allows a comprehensive understanding of the phenomena influencing the joint strength. In this study, ultrasonic welding was utilized to join copper to aluminum sheets of 0.3 mm thickness, and then the macro- and microstructural characteristics of the weld cross-section and interface were thoroughly investigated. Finally, the microstructural changes at different values of ultrasonic welding parameters were correlated with the mechanical strength characteristics. This research identified mechanical interlocking and interface diffusion as the primary welding mechanisms. With an increase in welding time from 0.2 to 0.8 s, the bond density rose, the post-weld thickness decreased, and the average Vickers hardness at various points along the weld interface decreased by 10%. © 2024 The Authors
  6. Keywords:
  7. Dissimilar welding ; Mechanical properties ; Microstructure evolution ; Ultrasonic metal welding ; Lithium-ion batteries ; Microstructure ; Plug-in hybrid vehicles ; Ultrasonic welding ; Vickers hardness ; Welds ; Dissimilar welding ; Joint strength ; Macro characteristics ; Mechanical properties analysis ; Microstructure evolutions ; Performance ; Plug-in-Hybrid Vehicles ; Solid-state welding process ; Ultrasonic metal welding ; Ultrasonic weldings ; Copper
  8. Source: Journal of Materials Research and Technology ; Volume 30 , 2024 , Pages 2922-2935 ; 22387854 (ISSN)
  9. URL: https://www.sciencedirect.com/science/article/pii/S223878542400810X