Skip to main content Accessibility help
×
Home

Modelling and Characterization of Ultrasonic Consolidation Process of Aluminium Alloys

  • Elaheh Ghassemieh (a1) and Elaheh Ghassemieh (a2)

Abstract

Ultrasonic consolidation process is a rapid manufacturing process used to join thin layers of metal at low temperatures and low energy consumption. In this work, finite element method has been used to simulate the ultrasonic consolidation of Aluminium alloys 6061 (AA-6061) and 3003 (AA-3003). A thermomechanical material model has been developed in the framework of continuum cyclic plasticity theory which takes into account both volume (acoustic softening) and surface (thermal softening due to friction) effects. A friction model based on experimental studies has been developed, which takes into account the dependence of coefficient of friction upon contact pressure, amount of slip, temperature and number of cycles. Using the developed material and friction model ultrasonic consolidation process has been simulated for various combinations of process parameters involved. Experimental observations are explained on the basis of the results obtained in the present study. The current research provides the opportunity to explain the differences of the behaviour of AA-6061 and AA-3003 during the ultrasonic consolidation process. Finally, trends of the experimentally measured fracture energies of the bonded specimen are compared to the predicted friction work at the weld interface resulted from the simulation at similar process condition. Similarity of the trends indicates the validity of the developed model in its predictive capability of the process.

Copyright

References

Hide All
1. Joshi, K.C., The formation of ultrasonic bonds between metals. Welding Journal, 1971. 50: p. 840848.
2. Kong, C.Y., Investigation of Ultrasonic consolidation for embedding active/passive fibres in aluminium matrices, in Rapid Manufacturing Center. 2005, Loughborough University: Loughborough, UK. p. 1207.
3. Kong, C.Y., Soar, R.C., and Dickens, P.M., Characterisation of aluminium alloy 6061 for the ultrasonic consolidation process. Materials Science and Engineering A, 2003. 360: p. 99106.
4. Kong, C.Y., Soar, R.C., and Dickens, P.M., Optimum process parameters for ultrasonic consolidation of 3003 aluminium. Journal of Materials Processing Technology, 2004. 146: p. 181187.
5. Krzanowski, J.E., A Transmission Electron Microscopy Study of Ultrasonic Wire Bonding. IEEE Trans. CHMT, 1990. 13: p. 176181.
6. Tucker, J.C., Ultrasonic welding of copper to laminate circuit board, in Materials Science & Engineering. 2002, Worcester Polytechnic Institute. p. 125.
7. Doumanidis, C. and Gao, Y., Mechanical Modelling of Ultrasonic Welding. Welding Journal, 2004. 4: p. 140146.
8. Chaboche, J.L., Time independent constitutive theories for cyclic plasticity. International Journal of Plasticity, 1986. 5: p. 247302.
9. Chaboche, J.L., Constitutive equations for cyclic plasticity and cyclic viscoplasticity. International Journal of Plasticity, 1989. 5: p. 247302.
10. ABAQUS, ABAQUS version 6.5, Online Documentation. 2006, Hibbit & Karlsson.
11. Cheng, X. and Li, X., Investigation of heat generation in ultrasonic metal welding using micro sensor arrays. J. Micromechanics and microengineering, 2007. 17(2): p. 273282.
12. Li, D., Defining Optimum Parameters for Embedding SiC fibres and influence on bond strength in Al 6061 matrix. 2007, Rapid Manufacturing Research Group, Loughborough University: Loughborough, UK. p. 119.
13. Li, D., Report for machine performance validation through comparison of peel strength and linear weld density of samples made before and after machine maintenance. 2007, Rapid Manufacturing Research Group, Loughborough University: Loughborough. p. 114.
14. Davis, J. R., ASM specialty handbook: Aluminium and aluminium aloys. 1993 ASM international Ohio.
15. Kaufman, J. G., Properties of Aluminium Alloys: Tensile, Creep, and Fatigue Data at High and Low Temperatures, 1999 ASM, Metals Park, OH 44073–0002, USA.
16. Hopperstad, O. S., Langseth, M., Remseth, S., Cyclic stress-strain behaviour of Alloy AA6060, Parth I: Uniaxial experiments and modeling. Int. J. Plasticity, 1995. 11: p. 725739.
17. Naidu, N. K. R, and Raman, S. G. S., Effect of contact pressure on fretting fatigue behaviour of Al-Mg-Si alloy. International Journal of Fatigue, 2005. 27: p. 283291.
18. Zhang, C. B., Zhu, X. J., and Li, L. J., A study of friction behaviour in ultrasonic welding (consolidation) of aluminium. AWS Conference: Session 7: Friction and resistance welding/materials bonding process, 2006.

Keywords

Modelling and Characterization of Ultrasonic Consolidation Process of Aluminium Alloys

  • Elaheh Ghassemieh (a1) and Elaheh Ghassemieh (a2)

Metrics

Full text views

Total number of HTML views: 0
Total number of PDF views: 0 *
Loading metrics...

Abstract views

Total abstract views: 0 *
Loading metrics...

* Views captured on Cambridge Core between <date>. This data will be updated every 24 hours.

Usage data cannot currently be displayed