Modal Analysis of Ultrasonic Spot Welding for Lightweight Metals Joining

Huang, Hui; Chen, Jian; Feng, Zhili; Sun, Xin

doi:10.3390/met13101735

Modal Analysis of Ultrasonic Spot Welding for Lightweight Metals Joining

Journal Article · Fri Oct 13 00:00:00 EDT 2023 · Metals

DOI:https://doi.org/10.3390/met13101735· OSTI ID:2202335

Huang, Hui; ; ; Sun, Xin

Ultrasonic spot welding (USW) represents one of the unique solid-state joining methods for lightweight materials such as magnesium alloy and aluminum alloy. However, the sonotrode vibration may have a detrimental impact on the sheet material and the existing welds, depending on the component geometry and vibration frequency. In this study, a modal analysis tool based on steady-state dynamics was developed for ultrasonic spot welding which features a cyclic load applied to the sheets during the joining process. Through predicting relative motion and shear stress at the faying surfaces, coupon geometry and weld spacing are identified as two major factors that affect the welding reliability and joint quality in USW. The model was validated via welding experiments on aluminum alloy and magnesium alloy and relevant characterization of temperature distribution, joint strength as well as fracture location.

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Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2202335

Alternate ID(s):: OSTI ID: 2203805

Journal Information:: Metals, Journal Name: Metals Journal Issue: 10 Vol. 13; ISSN MBSEC7; ISSN 2075-4701

Publisher:: MDPI AGCopyright Statement

Country of Publication:: Switzerland

Language:: English

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