Study of five Research Paper on Ultrasonic Welding

“Research Skill”
By
Kaumilkumar Pankajkumar Shah
(PG - AMS, 170050750006)
GUJARAT TECHNOLOGICAL UNIVERSITY
BABARIA INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
2017-18
A Presentation
on
Guided by,
Dr. R.V.Patil

Assignment - 1
Title: IMPACT FACTOR AND H-FACTOR OF RESEARCH PAPERS
 Journal Impact Factor:
The impact factor (IF) or journal impact factor (JIF) of an academic journal is a measure reflecting the yearly average
number of citations to recent articles published in that journal. It is frequently used as a proxy for the relative importance
of a journal within its field; journals with higher impact factors are often deemed to be more important than those with
lower ones.
In any given year, the impact factor of a journal is the number of citations, received in that year, of articles published in that
journal during the two preceding years, divided by the total number of articles published in that journal during the two
preceding years:
For example, Nature had an impact score of 41.456 in 2014:
This means that, on average, its papers published in 2012 and 2013 received roughly 41 citations each in 2014.
H-INDEX:
The definition of the index is that a scholar with an index of h has published h papers each of which has been cited in other
papers at least h times. Thus, the h-index reflects both the number of publications and the number of citations per publication.
The index is designed to improve upon simpler measures such as the total number of citations or publications. The index
works properly only for comparing scientists working in the same field; citation conventions differ widely among different
fields.
IFy = Citationsy-1 + Citationsv-2 .
Publicationsy-1+ Publicationsy-2

• Calculation : Formally, if f is the function that corresponds to the number of citations for each publication, we compute
the h index as follows. First we order the values of f from the largest to the lowest value. Then, we look for the last position in
which f is greater than or equal to the position (we call h this position). For example, if we have a researcher with 5
publications A, B, C, D, and E with 10, 8, 5, 4, and 3 citations, respectively, the h index is equal to 4 because the 4th
publication has 4 citations and the 5th has only 3. In contrast, if the same publications have 25, 8, 5, 3, and 3, then the index is
3 because the fourth paper has only 3 citations.
Table -1 : Impact Factor and H-factor of the technical papers referred
Sr. No. Paper Title Journal Publisher I-Factor H-Factor
1 Material flow in
ultrasonic vibration
enhanced friction stir
welding
Journal of
Materials
Processing
Technology
ELSEVIER 3.147 131
2
Dissimilar ultrasonic spot
welding of aerospace
aluminum alloyAA2139
to titanium alloy TiAl6V4
Journal of
Materials
Processing
Technology
ELSEVIER 3.147 131
3
Micro-ultrasonic welding
using thermoplastic-
elastomeric composite
film
Journal of
Materials
Processing
Technology
ELSEVIER 3.147 131
4
Ultrasonic welding
between mild steel sheet
and Al-Mg alloy sheet
Journal of
Materials
Processing
Technology
ELSEVIER 3.147 131
5
Modeling the effects of
ultrasonic vibration on
friction stir welding
Journal of
Materials
Processing
Technology
ELSEVIER 3.147 131

Assignment - 2
Title: Critical Information / Central Idea of each of the technical papers
❖ First Paper:
Title: Material flow in ultrasonic vibration enhanced friction stir welding
• Ultrasonic energy enlarged the volume of the deformed material around the pin, enhanced the stability of the
continuous material flow and the material strain of the noncontinuous flow obviously.
• The transverse cross-section of welds can be divided into three different material flow zones: the SAZ (shoulder-affected
zone),the PAZ (pin-affected zone) and the WBZ (weld-bottom zone).In contrast with FSW, the SAZ in UVeFSW
broadens in width and thickness, and the PAZ broadens in width and correspondingly thins in thickness.
[ Tensile strength and elongation of the welded joints ]

• The marker material (MM) was a thin foil of pure aluminum 1060 (thickness 0.2 mm),mainly aluminium alloy has very
high strength. So, welded joint has very high strength
• The improvement of weld joint quality in UVeFSW, Compare to FSW.
• Initially we used FSW and now, we are using to combine the Marker material distribution in FSW and UVeFSW
together.
 Second Paper:
Title: Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to titanium
alloy TiAl6V4
• The most frequently used aerospace titanium alloy (TiAl6V4) was joined to AA2139, a recently developed aerospace
Al-Cu-Mg-Ag alloy.
• The objective of this work is not only to assess the suitability of HP-USW for joining high strength aerospace
aluminum alloy to TiAl6V4, but also to investigate and evaluate the USWeld joints from both mechanical and
metallurgical points of view.
• The peak load that can be sustained before failure of the Al-Ti weld increased with an increase of welding time from 0
s to 2.0 s. For times longer than this, peak load plateaus, with an upper limit around 5.3 kN (~100 MPa, shear
strength).
• This peak load is much higher than that measured during testing of optimized Al-Mg USW welds (~2.0 kN) and Al-Fe
USW welds (~2.8 kN) of similar dimensions.
• The peak load and fracture energy of welds increased with an increase in welding time and then reached a plateau, i.e.,
maximum peak load 5.3 kN and maximum fracture energy 3.7 kN mm. In all cases, failure occurred by fracture at the
weld interface.

(a) Effect of welding time on the peak load and shear strength of AA2139/TiA16V4 USW welds,
(b)Effect of welding time on fracture energy of AA2139/TiAl6V4 welds.
 Third Paper:
Title: Micro-ultrasonic welding using thermoplastic-elastomeric composite film
• In conventional ultrasonic welding, the energy directors melt and flow across the surface of the samples, resulting in a
thinner fusion layer. In ultra-sonic welding using composite film, the energy directors melts but maintains itsheight due
flow restriction by the matrix material.
• The welding strength of the polydimethyl siloxane - polymethyl methacrylate microspheres composite film is up to 35 kPa.
• ultrasonic welding provides an option to compromise welding strength for better control of molten polymer flow and
problems of trapped air in welded samples.
 Fourth Paper:
Title: Ultrasonic welding between mild steel sheet and Al-Mg alloy sheet

 Fifth Paper:
Title: Modeling the effects of ultrasonic vibration on friction stir welding
• Authors investigated the influence of ultrasonic welding conditions on the mechanical properties and the interface
microstructure of a joint, and the effect of insert metal was examined to improve the joint strength.
• The strength of a joint welded using the constant clamping force of 588 N and various strength of a joint welded using the
welding time of 3.0 s deceased due to the formation of Fe2Al5 inter metallic compound at the interface.
• During the welding process, the ultrasonic vibration is directly transmitted into the plastically deformed material layer near
the FSW tool by a sonotrode.
• The ultrasonic vibration unit is ran with a frequency of20 kHz, an amplitude of 40 Micro meter and the efficient power of
300 W during the UVeFSW process.
• The distance between the axis of the sonotrode and the axis of the FSW tool is chosen as 20 mm.
• The radius of the sonotrode at the tip is 4.0 mm. ultra-sonic vibration reduces the yield stress of the plastically deformed
material near the tool which leads to relatively low plastic deformation heat generated at the tool work piece contact interfaces
during UVeFSW process.
• The sonotrode is inclined at 40 with respect to the horizontal axis. The clamping force of the sonotrode is 300 N during the◦
process.
• The tool axis was tilted by 2.5 with respect to the vertical axis during the welding process.◦
• UVeFSW has the potential to increase the welding speed and welding efficiency, and also ensure welding quality by
enhancing the plastic material flow near the tool
• The percent ultrasonic softening ranges from zero to one,depending on the ultrasonic parameters and the work piece
material

• The figure shows that the distance where the material flow velocity is reducedto welding speed (3 mm/s) increases
from 6.7 mm to 8.5 mm away from the tool axis on RS with superimposing ultrasonic vibration,while on the AS that
distance increases from 5.0 mm to 6.4 mm.
• It shows that superimposing ultrasonic vibration in friction stir welding leads to more intense plastic material flow.
Assignment - 3
Title: IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF
LITERATURE REVIEW
 First Paper:
• Initially, butt joint we are used Friction stir welding and now,we are using Ultrasonic energy to the workpiece near and
ahead of the rotating tool by a specially-designed sonotrode.
• In UVeFSW, the Marker material deposition was more concentrated, and the final position of the Marker material
deposited is 1.24mm from the weld centerline, which is nearer than that in FSW (2.06 mm). This observation result is
consistent with the Marker material distribution on transverse cross-sections.
• When weld RS & AS continuous flow of material mens linear flow in Shoulder Affected Zone, Pin Affected Zone &
Weld bottom Zone.
• The continuous flow (upper one third of weld) and the non-continuous flow (lower two thirds of weld).
• The material In UVeFSW, the Marker Material began to flow at an earlier time than that in FSW.This indicates that the
volume of the deformed material and its strain are larger in UVeFSW. Flow was more stable in UVeFSW.

❖ Second Paper:
Title: Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to titanium
alloy TiAl6V4
• Successful joining of dissimilar metals (Al and Ti) highly depends on the degree of interdiffusion between Al and Ti.
• When the inter-diffusion is sufficient, a diffusion zone or an IMC layer forms on the interface, which is necessary for
forming a sound dissimilar metal weld.
• The “temperature-rise phase” of AA2139/TiAl6V4 weld is much longer compared with that of AA6111/TiAl6V4 weld, as
a result, it took longer time to form a sound joint for the AA2139/TiAl6V4 combination than for the AA6111/TiAl6V4
combination.
• Similar to the ultrasonic welding thermal cycle of AA6111/TiAl6V4 joints, the welding thermal cycle of AA2139/TiAl6V4
can be divided into three phases:
1.Temperature-rise phase; 2. High temperature holding phase; 3.Cooling phase.
• The long “temperature-rise phase” of AA2139/TiAl6V4 weld led to poor bonding in welds produced using welding times
shorter than 2 s.
• The temperature at welding times 2 s is not high enough for sufficient inter-diffusion between AA2139 and TiAl6V4 to
form a fully bonded weld. This is consistent with the poor mechanical properties measured for such short time welds.
• Third Paper:
• This present study explores the feasibility of using a compositefilm made of distributed thermoplastic particles in an
elastomericmatrix to restrict the flow of melted energy directors and eliminate problems of trapped air, thus reducing its
impact on the shapes offlow channels of microfluidic devices.

• The design process includesthe matrix material selection, energy director distribution and opti-mizing the ultrasonic
welding process parameters.
• The welding strength of the polymethyl methacrylate (PMMA) and polydimethyl siloxane (PDMS) microspheres
composite filmis up to 35 kPa.
• Design of composite film to prevent overflow of PMMA during ultrasonic welding.
❖ Fourth Paper:
• The joint strength increased with the welding time up to 2.5 s. However, it decreased at the welding time of 3.0 s.
• The constant clamping force of 588 N,if we increased force then decreased tensile load(N) under constant welding
time 1.0s the welding time was changed from 0.1 s to 1.0 s using various clamping forces.
• The result indicates that the specimen temperature was below about 100 °C using 343 N clamping force because the
generation of frictional heat was insufficient, however, the specimen temperature increased up to about 400 °C using
the clamping forces of 588 N and 882 N, resulted in the larger joint strength.
❖ Fifth Paper:
• The heat generated by the FSW process in UVeFSW is lower than that in the conventional FSW
• ultrasonic vibration in friction stir welding process can produce an enhanced plastic material flow, increase the
welding speed and welding efficiency, and also improve the weld quality by enhancing the plastic material flow near
the tool

• the comparison of the calculated iso-viscosity line of 4.0 x 106kg m-1s-1in UVeFSW and conventional FSW for two
cases. It can be found that the calculated TMAZ boundaries (i.e., the iso-viscosity line of 4.0 x 106kg m-1s-1) in
UVeFSW are larger than that in the conventional FSW for both the cases.
• The temper-ature distribution near the tool for U-600-180 is almost the same to that for C-600-180 as shown in Fig. 5,
while the iso-viscosityregion of 4.0 x 106kg m-1s-1in UVeFSW is still larger than that in conventional FSW as shown
in Fig. 13a. That means it is not thermal softening but ultrasonic softening which leads to the relatively larger TMAZ
boundary with superimposing ultrasonic vibration.
• Both experimental and numerical simulation results shown that the superimposed ultrasonic vibration in FSW can
enhance the potential to increase the welding speed and welding efficiency, and also ensure welding quality by
enhancing the plastic material flow near the tool.
• The ultrasonic energy is sufficient to reduce the flow stress of the material to zero, which is an extreme case.
• The peak value in UVeFSW is about 2200 kW/m2, while it is about2600 kW/m2in the FSW process
• The ultrasonic vibration reduces the contact shear stress at tool work piece interfaces, which leads to a relatively lower
heat generation rate at the tool workpiece contact interfaces but an enhanced plastic material flow around the tool in
UVeFSW.
Assignment - 4
Title: Statement of the Problem in each of the technical paper
 First Paper:
• Typical weld profiles on transverse cross-section Sharp corner shows,
• Recognition of the sharp corner horizontal cross-sections of the weld at the plane,

• Unfilled zone to sharing edge - Horizontal cross-section with the exit hole at plane z = 2.4mm
• In this case all the MM was transferred to the back of the original position, and just a little of them crossed the weld
centerline and deposited on the Advancing side weld. The farthest distance of the MM from the original position is
4.93mm in FSW
Horizontal cross-section with the exit hole at plane z = 2.4mm: (a) FSW ,(b) UVeFSW
❖ Second Paper:
Title: Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to
titanium alloy TiAl6V4

• Laser lap welded Al (AA5754) and Ti (T40) using a Al-Si filler wire, and an IMC layer mainly composed of Al 3 Ti with a
thickness varying from 0.5 to 2.4 mm was observed on the weld interface.
• Brazed 6061 aluminum alloy and Ti6Al4V using an Al-Si-Cu-Ge-Re filler metal, and an Al 5 Si 12 Ti 7 intermetallic
compound (IMC) layer with a thickness of 3-6 micro was observed on the weld interface.
• Welded Ti6Al4V titanium sheet and Al 5A06 sheet together by laser brazing with a filler wire made from aluminum alloy.
Both Ti 7 Al 5 Si 12 and Al 3 Ti phases were observed in the reaction layer. The thickness of the reaction layer varies from
a few microns to around 50 Dm depending on the welding parameters.
 Third Paper:
• In conventional ultrasonic welding, the energy directors melt and flow across the surface of the samples, resulting in a
thinner fusion layer.
 Fourth Paper:
• The friction welding has the restriction in shape that at least one material to be welded should be circular in cross-section.
The rolling has also shortcoming that it is applicable to only a thin plate.
• Hard and brittle inter metallic compounds were formed at the weld whenever steel was welded to aluminum by fusion
welding.
• At present, the following bonding methods have been employed to produce the joint between steel and aluminum, that is to
say, friction welding, resistance spot welding, rolling and modified FSW.

 Fifth Paper:
• Large spindle torque and downward force are needed to generate the necessary heat energy and material softening to
facilitate sufficient plastic material flow near the tool.
• Furthermore, the high stress imposed on the tool pin during the FSW process causes rapid tool wear and premature tool
failure, which results in poor weld quality and high production cost.
• In addition, the higher welding load during the FSW process also limits the welding speed.
Assignment - 5
Title: Various Methods Used in Research Papers
❖ First Paper:
• Ultrasonic energy was transmitted directly into the localized area of the work piece near and ahead of the rotating tool
by a specially-designed sonotrode.
• By the experimentle method material is stable flow and no edges and sharp corner seen, So, no need to validate.
SAZ
WeldingPAZ
directionWBZ
SAZ
PAZ
WBZ
Welding
direction
Sketch map of three-dimensional material flow around the pin: (a) FSW; (b) UVeFSW

direction
corner
Welding
direction
Unit:mm
Welding
Sharp
WBZ Umt:mm
SAZ
Typical weld profiles on transverse cross-section: (a) FSW; (b) UVeFSW
 Second Paper:
Title: Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to titanium alloy
TiAl6V4
• In this study, the most frequently used aerospace titanium alloy (TiAl6V4) was joined to AA2139, a recently developed
aerospace Al-Cu-Mg-Ag alloy.
• The objective of this work is not only to assess the suitability of HP-USW for joining high strength aerospace aluminum
alloy to TiAl6V4, but also to investigate and evaluate the USWeld joints from both mechanical and metallurgical points of
view.
• The samples for microstructural investigations were cross-sectioned perpendicular to the welding direction, which is
parallelto the ultrasonic vibration direction, and prepared for metallographic investigation using standard methods.

• The microstructurenear the interface was observed with back-scattered electrons using an FEI Quanta 650 field
emission scanning electron microscopy (FE-SEM) equipped with an energy-dispersive X-rays pectroscopy (EDS)
detector. So,no need to validate.
 Third Paper:
•
(a) conventional and (b) composite film ultra-sonic welding
 In conventional ultrasonic welding, the energy directors melt and flow across the surface
of the samples, resulting in a thinner fusion layer.
 In ultra-sonic welding using composite film, the energy directors melts but maintains its
height due flow restriction by the matrix material.
• By the experiment,In ultra-sonic welding using composite film, the energy directors melt but maintains its height
due flow restriction by the matrix material.So no need to validate

 Fourth Paper:
• In this study, authors tried to weld ultrasonically mild steel sheet to aluminum alloy sheet containing magnesium and
investigated the effect of welding conditions on the mechanical properties and the interface micro structure of a joint.
• Furthermore, the effect of insert metal was investigated to improve the joint properties.So,no need to validate.
Relation between tensile load of a joint and welding time

Relation between tensile load of a joint welded using an insert metal and clamping force
 Fifth Paper:
• The model is validated by a comparison of the calculated thermal cycles and thermo mechanically affected zone
boundaries with the experimentally measured ones.
• The comparison of the calculated iso-viscosity line of 4.0 x 106kg m-1s-1in UVeFSW and conventional FSW for
two cases. It can be found that the calculated TMAZ boundaries (i.e., the iso-viscosity line of 4.0 x 106kg m-1s-1)
in UVeFSW are larger than that in the conventional FSW for both the cases.

Unit: kg-m'-s
1.0E+06 2.0E+06 3.0E+06 4.0E+06 5.0E+06
* ~
:: .-';
v XlrJ&trJS JOS
wer-■ *? w v.
%
j
mm
. AS
U-600-180UVeFSW
Y (mm)
2 mm
aA&S
cFSW
(Y mm)
The comparison of the viscosity field with the experimental macrostructure at transverse
cross-section: (a) UVeFSW and (b) FSW.
(The black dotted line is the measured TMAZ boundary).

-40 -20
X (mm)
(a) the top
surface of the
work piece
(b) The
transverse
cross-section

Assignment - 6
Title: Key Features of the Technical Research papers
 First Paper:
• Friction stir welding using ultrasonic vibration, the ultrasonic vibration improves the laminar flow stability.
• For non-continuous material flow in Pin Affected Zone, the ultrasonic vibration increases the material strain obviously,
resulting in the weakening of the vertical material transfer.
• When weld RS & AS continuous flow of material mens linear flow in Shoulder Affected Zone,Pin Affected Zone & Weld
bottom Zone.
• The continuous flow (upper one third of weld) and the non-continuous flow (lower two thirds of weld).
• The material In UVeFSW, the Marker Material began to flow at an earlier time than that in FSW.
• This indicates that the volume of the deformed material and its strain are larger in UVeFSW. Flow was more stable in
UVeFSW.
 Second Paper:
Title: Dissimilar ultrasonic spot welding of aerospace aluminum alloy
AA2139 to titanium alloy TiAl6V4
• The indent area increased with increasing welding time, due to the softening of AA2139 aluminum alloy and the downward
movement of the welding tip with increasing welding time.
• Thin foils for transmission electron microscopy (TEM) were pre-pared by Focused Ion Beam Milling (FIB) using a FEI
QUANTA 3D FIB system operating at 30 kV for rough cutting and milling, and both5 kV and 2 kV for final cleaning.

 Third Paper:
• The foils were examined using a Tecnai TF30 transmission electron microscope operating at 300 kV.
• The welding time, which ranged from 0 s to 4 s, is the only variable parameter in this study.
• The welding energy is simply proportional to the welding time and has a maximum of approximately 4 kJ, as the weld
power is kept constant.
• The pressure applied was also kept constant at 0.55 MPa.
• The sonotrode tip was of circular cross section with a diameter of 10 mm.
• It was aligned at the centre of a 25 mm overlap between the sheets when ultrasonic spot welding was performed.
• welding using composite film made of polydimethyl siloxane - polymethyl methacrylate microspheres, the energy directors
melts but maintains its height due flow restriction by the matrix material.
• Design of composite film to prevent overflow of PMMA during ultrasonic welding.
• The proposed methodology of ultrasonic welding provides an option to compromise welding strength for better control of
molten polymer flow and problems of trapped air in welded samples.
• The PMMA microspheres with precise concentration into a polydimethyl siloxane mixture of a fixed recipe of 184 silicone
elastomer base and curing agent at a ratio of 10:1, spin coated the mixture onto a polymethyl methacrylate substrate and cured it
at 80 C for30 min.◦

 Fourth Paper:
• The authors ultrasonically welded the mild steel sheet to the aluminum alloy sheet containing magnesium and
investigated the effect of welding conditions on the mechanical properties and the interface microstructure of the joint.
• Using the insert metal of commercially pure aluminum successfully improved the joint strength and the joint strength
welded using 3.0 s welding time was about three times as large as that of the joint without the insert metal.
• The welding condition is 588N clamping force and the welding times of 0.5-3.0 s. The strength of the joint is higher
Tensile load about 1800 N
❖ Fifth Paper:
• Superimposing ultrasonic vibration to the tool needs a complex mechanical linkage between the ultra-sonic unit and the
FSW tool,
which causes inconvenience to change tools with different size and design under different cases.
• The ultrasonic vibration is directly transmitted into the localized area of the workpiece near and ahead of the rotating
tool and the process is termed as ultrasonic vibration enhanced FSW (UVeFSW)
• The ultrasonic vibration unit is ran with a frequency of 20 kHz, an amplitude of 40 micro meter and the efficient
power of 300 W during the UVeFSW process
• The percent ultrasonic softening ranges from zero to one, depending on the ultrasonic parameters and the work piece
material.
• The ultrasonic energy is sufficient to reduce the flow stress of the material to zero, which is an extreme case.

• The material flow velocity is reduced to welding speed (3 mm/s) increases from 6.7 mm to 8.5 mm away from the
tool axis on RS with superimposing ultrasonic vibration, while on the AS that distance increases from 5.0 mm to 6.4
mm.
• It shows that superimposing ultrasonic vibration in friction stir welding leads to more intense plastic material flow.
• Superimposing ultrasonic vibration in friction stir welding can increase the material flow velocity, enlarge the flow
region, decrease the viscosity and enlarge the iso-viscosity region near the tool comparing with that in conventional
FSW process.

Study of five Research Paper on Ultrasonic Welding

Study of five Research Paper on Ultrasonic Welding

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