Microstructural Characterization of Ultrasonically Welded Aluminum

Author:

Allameh S. M.1,Mercer C.2,Popoola D.3,Soboyejo W. O.4

Affiliation:

1. Department of Technology, Northern Kentucky University, Highland Heights, KY 41076

2. Materials Department, University of California at Santa Barbara

3. Zimmer, Inc., Warsaw, IN 46581

4. Princeton Materials Institute and The Department of Mechanical and Aerospace Engineering, Princeton University, Princeton, NJ 08544

Abstract

The microstructure and mechanical properties of ultrasonically welded AA6111-T4 specimens are discussed. The effects of welding time on the mechanical properties of welded joints are investigated. A longer welding time results in a more continuous welded interface and higher yield and fracture strengths. Accordingly, fatigue properties of the welded specimens with longer welding times are improved. The results of electron microscopy on the cross section of ultrasonically welded joints show three distinct zones: weld zone, weld affected zone and compression zone each with a distinct microstructure. TEM results show nanocrystalline grains along with second phase particles in the range of 15–25 nm in the weld zone. Flow patterns consistent with the geometry of weld–tip were observed at the weld interface.

Publisher

ASME International

Subject

Mechanical Engineering,Mechanics of Materials,Condensed Matter Physics,General Materials Science

Reference46 articles.

1. Yabunaka, K., 1980, “Connecting armature coil to core-bending lead wires and connecting to commutator segments by ultrasonic welding process,” WO-8002479 A.

2. Bokarev, D. I., Zenin, V. V., and Segal, Y. E., 2002, “Internal termination ultrasonic welding in power semiconductors,” Presented in Tekhnika Mashinostroeniya, Izdatel’stvo ‘Virazh-Tsentr,’ pp. 30–33.

3. “Ford goes for ultrasonic weld,” Prof. Eng., Anon., 2003, 16, p. 48.

4. Devine, J., 1984, “ULTRASONIC WELDING OF ALUMINUM ALLOY SHEET METAL,” Presented in Sheet Metal Welding Conference: The Latest Technology for Sheet Metal Joining-Conference Proceedings., Miami, FL, USA, AWS.

5. Heinz, A., Haszler, A., Keidel, C., Moldenhauer, S., Benedictus, R., and Miller, W. S., 2000, “Recent development in aluminum alloys for aerospace applications,” Mater. Sci. Eng., A, 280(1), pp. 102–107.

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