Theoretical and FE analysis of ultrasonic welding of aluminum alloy 3003

A. Siddiq*, E. Ghassemieh, Muhammad Amir

*Corresponding author for this work

Research output: Contribution to journalArticle

44 Citations (Scopus)

Abstract

Ultrasonic welding (consolidation) process is a rapid manufacturing process that is used to join thin layers of metal at low temperature and low energy consumption. Experimental results have shown that ultrasonic welding is a combination of both surface (friction) and volume (plasticity) softening effects. In the presented work, an attempt has been made to simulate the ultrasonic welding of metals by taking into account these effects (surface and volume). A phenomenological material model has been proposed, which incorporates these two effects (i.e., surface and volume). The thermal softening due to friction and ultrasonic (acoustic) softening has been included in the proposed material model. For surface effects, a friction law with variable coefficient of friction that is dependent on contact pressure, slip, temperature, and number of cycles has been derived from experimental friction tests. The results of the thermomechanical analyses of ultrasonic welding of aluminum alloy have been presented. The goal of this work is to study the effects of ultrasonic welding process parameters, such as applied load, amplitude of ultrasonic oscillation, and velocity of welding sonotrode on the friction work at the weld interface. The change in the friction work at the weld interface has been explained on the basis of softening (thermal and acoustic) of the specimen during the ultrasonic welding process. In the end, a comparison between experimental and simulated results has been presented, showing a good agreement.

Original languageEnglish
Pages (from-to)0410071-04100711
Number of pages3690641
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume131
Issue number4
DOIs
Publication statusPublished - 1 Aug 2009

Fingerprint

Ultrasonic welding
Aluminum alloys
Friction
Welds
Ultrasonics
Acoustics
Metals
Consolidation
Plasticity
Welding
Energy utilization
Temperature

Keywords

  • Aluminum alloy 3003
  • Friction laws
  • Thermomechanical analysis
  • Ultrasonic consolidation
  • Ultrasonic metal welding
  • Ultrasonic softening

ASJC Scopus subject areas

  • Computer Science Applications
  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering
  • Mechanical Engineering

Cite this

Theoretical and FE analysis of ultrasonic welding of aluminum alloy 3003. / Siddiq, A.; Ghassemieh, E.; Amir, Muhammad.

In: Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 131, No. 4, 01.08.2009, p. 0410071-04100711.

Research output: Contribution to journalArticle

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