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Impact of ultrasonic welding on multi-layered Al–Cu joint for electric vehicle battery applications : a layer-wise microstructural analysis
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Dhara, Sisir and Das, Abhishek (2020) Impact of ultrasonic welding on multi-layered Al–Cu joint for electric vehicle battery applications : a layer-wise microstructural analysis. Materials Science and Engineering: A, 791 . 139795. doi:10.1016/j.msea.2020.139795 ISSN 0921-5093.
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WRAP-impact-ultrasonic-welding-multi-layered-Al–Cu-joint-electric-vehicle-battery-applications-Das-2020.pdf - Accepted Version - Requires a PDF viewer. Available under License Creative Commons Attribution Non-commercial No Derivatives 4.0. Download (4Mb) | Preview |
Official URL: https://doi.org/10.1016/j.msea.2020.139795
Abstract
Multi-layered aluminium (Al) tabs to copper (Cu) busbar joints are increasingly being used for electric vehicle (EV) battery applications. Being a solid-state joining process, ultrasonic welding (USW) offers several benefits including less intermetallic or no porosity formation and larger weld area compared to fusion type welding, especially for highly conductive /reflective multi-layered dissimilar materials welding. In spite of being a suitable joining process, the impact of ultrasonic process parameters needs in-depth analysis for multi-layered stack-up where the process parameters play a pivotal role to join the layers of weldments. In this study, three layers of 0.3 mm Al tabs were welded to 1.0 mm single Cu busbar for the investigations of multi-layered Al-Cu dissimilar joints. Joint macro and microstructures, welding mechanism, layer-wise micro-hardness and grain formation were studied to understand the flow of material, the formation of grains and mixing of the Al and Cu for under-weld, good-weld and over-weld categories. The effects of amplitude of ultrasonic vibration, welding pressure and welding time were investigated to produce the satisfactory tab-to-busbar connection. The layer-wise microstructural study revealed the welding mechanism, propagation of micro-bonds and flow of material. The micro-hardness study unveiled different weld zones indicating the area of material mixing and the affected region whereas the crystallographic orientation maps disclosed the grain formation and recrystallization after the welding. The results showed that interfacial material mixing, wave-like material flow and interfacial micro-bonds formation were the prominent reasons for the satisfactory ultrasonic weld.
| Item Type: | Journal Article | ||||||||
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| Subjects: | T Technology > TA Engineering (General). Civil engineering (General) T Technology > TJ Mechanical engineering and machinery T Technology > TL Motor vehicles. Aeronautics. Astronautics T Technology > TS Manufactures |
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| Divisions: | Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group) | ||||||||
| Library of Congress Subject Headings (LCSH): | Electric vehicles -- Batteries , Ultrasonic welding, Joints (Engineering) | ||||||||
| Journal or Publication Title: | Materials Science and Engineering: A | ||||||||
| Publisher: | Elsevier S.A. | ||||||||
| ISSN: | 0921-5093 | ||||||||
| Official Date: | 22 July 2020 | ||||||||
| Dates: |
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| Volume: | 791 | ||||||||
| Article Number: | 139795 | ||||||||
| DOI: | 10.1016/j.msea.2020.139795 | ||||||||
| Status: | Peer Reviewed | ||||||||
| Publication Status: | Published | ||||||||
| Access rights to Published version: | Restricted or Subscription Access | ||||||||
| Date of first compliant deposit: | 1 July 2020 | ||||||||
| Date of first compliant Open Access: | 21 June 2021 | ||||||||
| RIOXX Funder/Project Grant: |
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