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Process robustness and strength analysis of multi-layered dissimilar joints using ultrasonic metal welding
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Das, Abhishek, Masters, Iain and Williams, D. K. (2019) Process robustness and strength analysis of multi-layered dissimilar joints using ultrasonic metal welding. The International Journal of Advanced Manufacturing Technology, 101 . pp. 881-900. doi:10.1007/s00170-018-2936-3 ISSN 0268-3768.
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Official URL: http://dx.doi.org/10.1007/s00170-018-2936-3
Abstract
This paper investigates the effects of process parameters on the joint strength and process robustness when multi-layered joints of dissimilar metals are produced by ultrasonic metal welding (UMW). Three layers of 0.3-mm aluminium sheet are welded with a single 1.0-mm copper sheet which is representative of electric vehicle battery interconnects. A process robustness study in which welding pressure, amplitude of vibration and welding time are varied to produce satisfactory welds is reported. The weld quality is evaluated by performing lap shear and T-peel tests where maximum loads are considered as the quality indicator. Response surfaces are developed to identify the relationship and sensitivity between the input process parameters and output quality indicators. A feasible weldability zone is defined for the first time by identifying the under-weld, good-weld and over-weld conditions based on load-displacement curves and corresponding failure modes. Relying on the weldability zone and response surfaces, multi-objective optimisation is performed to obtain maximum lap shear and T-peel strength which resulted in Pareto frontier or trade-off curve between both objectives. An optimal joint is selected from the Pareto front which is verified and validated by performing confirmation experiments, and further, used for T-peel strength analysis of different interfaces of the multi-layered joint. To conclude, this paper determines both the optimal weld parameters and the robust operating range.
Item Type: | Journal Article | ||||||||
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Subjects: | T Technology > TS Manufactures | ||||||||
Divisions: | Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group) | ||||||||
Library of Congress Subject Headings (LCSH): | Ultrasonic welding, Production engineering, Welded joints -- Testing, Interconnects (Integrated circuit technology), Electric vehicles -- Batteries, Robust optimization, Response surfaces (Statistics), Experimental design | ||||||||
Journal or Publication Title: | The International Journal of Advanced Manufacturing Technology | ||||||||
Publisher: | Springer-Verlag | ||||||||
ISSN: | 0268-3768 | ||||||||
Official Date: | 17 March 2019 | ||||||||
Dates: |
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Volume: | 101 | ||||||||
Page Range: | pp. 881-900 | ||||||||
DOI: | 10.1007/s00170-018-2936-3 | ||||||||
Status: | Peer Reviewed | ||||||||
Publication Status: | Published | ||||||||
Access rights to Published version: | Open Access (Creative Commons) | ||||||||
Date of first compliant deposit: | 23 November 2018 | ||||||||
Date of first compliant Open Access: | 23 November 2018 | ||||||||
RIOXX Funder/Project Grant: |
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