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“Why Ultrasonic Welding is useful compared to Normal Welding”
By
Kaumilkumar Pankajkumar Shah
(PG - AMS, 170050750006)
GUJARAT TECHNOLOGICAL UNIVERSITY
BABARIA INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
2018-19
A Presentation
on
 Introduction
 Central Idea of each of the technical papers
 Identified The Research Gap
 Statement of the Problem in each of the technical paper
 Various Methods Used in Research Papers
 Key Features of the Technical Research papers
 Literature Review and References
INTRODUCTION:
In 1938, Lludwig Bergman and some colleagues were experimenting with ultrasonic Waves and their
effects on metal. He found that many metals could be combined by using ultrasonic welding that
could not be joined by any other method. It was also found that any metal could be strengthened by
subjecting the metal in its molten state to ultrasonic vibrations.
The ultrasonic effect upon the molten metal generates a smaller grain size, giving the metal more
strength.
Ultrasonic welding combines pressure and high frequency vibration motions to form a solid state
bond.
The range ultrasonic frequency used in this welding is from 20kHz to 60kHz. This cool, strong weld
capable of joining such combination as aluminium to steel, aluminium to tungsten, aluminium to
molybdenum and nickel to brass.
Ultrasonic welding has also made it possible to join metals with vastly different melting
temperatures, making strong rigid joints. Thus many applications previously considered unweldable
can now revaluated.
WORKING:
UMW consists of an ultrasonic generator, which generates a frequency of 20 kHz to 40 kHz from a
supply of 220v/50Hz. The converter transforms the high frequency electric energy produced by the
generator in to mechanical energy. The booster serves as an amplitude transformer for the required
amplitude range as well as a general stabilizer for the oscillations of the transducer system. The
sonotrode or horn is the working tool of the ultrasonic metal welding.
The pieces to be welded are clamped between the welding tip called sonotrode and anvil. Both tip
and anvil are faced with high-speed steel, since considerable wear can occur at the contacting
surface. The process of ultrasonic welding is fairly simple. It begins when the parts those are to be
welded, such as two multi-strand copper wires for example, are placed together in the welding unit.
The system then compresses the wires together with a force of between 50 and several 100 pounds
per square inch to form a close connection between the two pieces. Next, the ultrasonic horn is used
to vibrate the two pieces together at a rate of around 20000 or 40000 Hz, depending on the
application.
Before the interaction of the pieces at the interface can be explained, some basic molecular physics
must be reviewed. The first principal is that when two clean pieces of metal are placed in intimate
contact, they will begin to share electrons, thus welding together, second, at atomic scale even
surfaces those that look perfect and smooth are very rough and impure.
The majority of these impurities are in the form of metal oxides that were produced when the
bare metal was exposed to the atmosphere. The second part of contamination is in the form of
ordinary dirt and oils. These impurities form a layer that prevents the electrons in the two parts
from passing between them, thus preventing them from welding together. In addition, the rough
surface prevents the metals from being in intimate contact, which also prevents the exchange of
electrons
Ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations
are locally applied to workpieces being held together under pressure to create a solid-state weld. It is
commonly used for plastics, and especially for joining dissimilar materials.
How does ultrasonic soldering work?
Instead of chemical agents, surface oxide layers are removed from the soldered surface by using
vibrations and a cavitation phenomenon. Ultrasonic soldering technology is different
from ultrasonic plastic welding, in which the vibrations generate heat to melt the parts being joined.
Principle A high frequency (20 kHz to 40 kHz)ultrasonic vibration is used to join two plastic pieces together. The
high frequency vibration generates heat energy at the interface of the two pieces and melts the material
How does ultrasonic welding work?
How Ultrasonic Welding Works. Ultrasonic welding is an industrial technique whereby high-
frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to
create a solid-state weld. It is commonly used for plastics, and especially for joining dissimilar materials
RF welding (also known as High Frequency (HF) welding or Dielectric welding) is a method of joining thin sheets
of polar thermoplastic material together. It uses high frequency (13 to 100 MHz) electromagnetic energy to fuse
the materials. A rapidly alternating electric field is set up between two metal welding bars.
Ultrasonic Welding Process
The ultrasonic welder machine will comprise of components such as – Transducer, Sonotrode and Anvil. The
complete welding mechanism will include the following steps:
1. A stationary clamping force is put exactly perpendicular to the interface in between the work pieces.
2. Then the contacting sonotrode of the welder oscillates parallel to the interface.
3. This coalesced effect of stationary and oscillating force generates deformation which furthers welding.
Advantages:
•It can be applied to miscellaneous combination of material welding and allows welding of thick and thin sections.
•Simplified welding of high and heat conduction materials such as copper, gold, aluminum, silver, etc.
•he pressures used for welding are low along with low consumption power.
•The time taken for welding is less and the width of deformed areas are thinner than that for the cold welding.
Disadvantages:
•Ultrasonic metal welding needs more power with the work piece as width and hardness increase exponentially.
•This welding process is limited to lap joints.
•It is dependent on material deformation under tooling.
•It might create audible noise from the part resonance.
Application:
It is mostly used in computer and electrical, aerospace and automotive, medical, and
packaging industries.
• Computer and Electrical Industries: Here it is used to join wired connections and to create
connections in small delicate circuits
• Aerospace and Automotive Industry
In automotive industries it is used to assemble large plastic and electrical components such as door
panels, instrument panels, air ducts, lamps, steering wheels, and upholstery and engine components.
In aerospace it is used to join thin sheet gauge and lightweight materials like aluminum.
• Medical Industry
It does not introduce any contaminants or degradation into the weld. That’s why it is used in medical
industries.
Items such as anesthesia filters, arterial filters, blood filters, dialysis tubes, pipettes, blood/gas filters,
cardiometry reservoirs etc. can be made using ultrasonic welding method.
• Packaging Industry
It is used to package different materials in food industries.
It is used for packaging dangerous materials like explosives, fireworks and chemical.
Critical Information / Central Idea of each of the technical papers
• 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 ]
 Research 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 marker material (MM) was a thin foil of pure aluminum 1060 (thickness 0.2 mm),mainly aluminum
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.
IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW
• 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 means 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.
• 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.
Statement of the Problem in each of the technical paper
Horizontal cross-section with the exit hole at plane z = 2.4mm:
(a) FSW ,(b) UVeFSW
Various Methods Used in Research Papers
• 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 experimental method material is stable flow and no edges and sharp corner seen, So, no need
to validate.
Sketch map of three-dimensional material flow around the pin: (a) FSW; (b) UVeFSW
Typical weld profiles on transverse cross-section:
(a) FSW; (b) UVeFSW
Key Features of the Technical Research papers
• 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.
Critical Information / Central Idea of each of the technical papers
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 US Weld 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.
IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW
• 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.
Title: Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to titanium alloy
TiAl6V4
Statement of the Problem in each of the technical paper
• 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.
Various Methods Used in Research Papers
• 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.
Key Features of the Technical Research papers
• 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.
• The foils were examined using a Tenia 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 center of a 25 mm overlap between the sheets when ultrasonic spot welding was
performed.
Title: Micro-ultrasonic welding using thermoplastic-elastomeric composite film
Critical Information / Central Idea of each of the technical papers
• 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.
• The welding strength of the polymethyl 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.
IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW
• This present study explores the feasibility of using a composite film made of distributed thermoplastic
particles in an elastomeric matrix to restrict the flow of melted energy directors and eliminate problems of
trapped air, thus reducing its impact on the shapes off low channels of microfluidic devices.
• The design process includes the matrix material selection, energy director distribution and opti-mizing
the ultrasonic welding process parameters.
• The welding strength of the polymethyl methacrylate (PMMA) and polymethyl siloxane (PDMS)
microspheres composite film is up to 35 kPa.
• Design of composite film to prevent overflow of PMMA during ultrasonic welding.
Statement of the Problem in each of the technical paper
• In conventional ultrasonic welding, the energy directors melt and flow across the surface of the samples,
resulting in a thinner fusion layer.
Various Methods Used in Research Papers
• 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
• 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.
(a) conventional and (b) composite film ultra-sonic welding
Key Features of the Technical Research papers
• welding using composite film made of polymethyl 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 polymethyl 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.
Critical Information / Central Idea of each of the technical papers
Title: Ultrasonic welding between mild steel sheet and Al-Mg alloy sheet
• 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.
IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW
• 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
Statement of the Problem in each of the technical 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.
Various Methods Used in Research Papers
• 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
Key Features of the Technical Research papers
• 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
Critical Information / Central Idea of each of the technical papers
Title: Modeling the effects of ultrasonic vibration on friction stir welding
• 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.
IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW
• 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 temperature 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-viscosity region 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.
Title: Material flow in ultrasonic vibration enhanced friction stir welding
Statement of the Problem in each of the technical 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.
Various Methods Used in Research Papers
• 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
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).
(a) the top surface of
(b) the work piece
(b) The
transverse
cross-section
Key Features of the Technical Research papers
• 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.
Title: Literature Review
Sr. No. Paper Title Journal Publisher Year of Publication
1 Material flow in ultrasonic
vibration enhanced friction stir
welding
Journal of Materials
Processing Technology ELSEVIER 2015
2 Dissimilar ultrasonic spot welding
of aerospace aluminum
alloyAA2139 to titanium alloy
TiAl6V4
Journal of Materials
Processing Technology ELSEVIER 2016
3 Micro-ultrasonic welding using
thermoplastic-elastomeric
composite film
Journal of Materials
Processing Technology ELSEVIER 2016
4 Ultrasonic welding between mild
steel sheet and Al–Mg alloy sheet
Journal of Materials
Processing Technology ELSEVIER 2009
5 Modeling the effects of ultrasonic
vibration on friction stir welding
Journal of Materials
Processing Technology ELSEVIER 2015
References:
C.Q. Zhanga,b, J.D. Robsona, P.B. Prangnellaa, Dissimilar ultrasonic spot welding of aerospace aluminum
alloyAA2139 to titanium alloy TiAl6V4, Journal of Materials Processing Technology 231 (2016) 382–388
Amini, S., Amiri, M.R., 2014. Study of ultrasonic vibrations’ effect on friction stir welding. Int. J. Adv.
Manuf. Technol. 73, 127–135.
Wei Xuan Chana,b, Sum Huan Ngb, King Ho Holden Lia, Woo-Tae Parkc, Yong-Jin Yoona, Micro-ultrasonic
welding using thermoplastic-elastomeric composite film, Journal of Materials Processing Technology
236 (2016) 183–188
Amini, S., Amiri, M.R., 2014. Study of ultrasonic vibrations’ effect on friction stir welding. Int. J. Adv.
Manuf. Technol. 73 (1–4), 127–135.
Lee, T., Lakes, R.S., Lal, A., 2000. Resonant ultrasound spectroscopy for measurementof mechanical
damping: comparison with broadband viscoelastic spectroscopy.Rev. Sci. Instrum. 71 (7), 2855–2861.
Nandan, R., DebRoy, T., Bhadeshia, H.K.D.H., 2008. Recent advances in friction-stir welding–process,
weldment structure and properties. Prog. Mater. Sci. 53,
980–1023.
L. Shia, C.S. Wua, X.C. Liua, Modeling the effects of ultrasonic vibration on friction stir welding, Journal
of Materials Processing Technology 222 (2015) 91–102
Takehiko Watanabe, Hideo Sakuyama, Atsushi Yanagisawa, Ultrasonic welding between mild steel sheet
and Al–Mg alloy sheet, Journal of Materials Processing Technology 209 (2009) 5475–5480
X.C. Liu, C.S. Wu, Material flow in ultrasonic vibration enhanced friction stir welding, Journal of
Materials Processing Technology 225 (2015) 32–44
Ultrasonic Welding Introduction including research paper

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Ultrasonic Welding Introduction including research paper

  • 1. “Why Ultrasonic Welding is useful compared to Normal Welding” By Kaumilkumar Pankajkumar Shah (PG - AMS, 170050750006) GUJARAT TECHNOLOGICAL UNIVERSITY BABARIA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering 2018-19 A Presentation on
  • 2.  Introduction  Central Idea of each of the technical papers  Identified The Research Gap  Statement of the Problem in each of the technical paper  Various Methods Used in Research Papers  Key Features of the Technical Research papers  Literature Review and References
  • 3. INTRODUCTION: In 1938, Lludwig Bergman and some colleagues were experimenting with ultrasonic Waves and their effects on metal. He found that many metals could be combined by using ultrasonic welding that could not be joined by any other method. It was also found that any metal could be strengthened by subjecting the metal in its molten state to ultrasonic vibrations. The ultrasonic effect upon the molten metal generates a smaller grain size, giving the metal more strength. Ultrasonic welding combines pressure and high frequency vibration motions to form a solid state bond. The range ultrasonic frequency used in this welding is from 20kHz to 60kHz. This cool, strong weld capable of joining such combination as aluminium to steel, aluminium to tungsten, aluminium to molybdenum and nickel to brass. Ultrasonic welding has also made it possible to join metals with vastly different melting temperatures, making strong rigid joints. Thus many applications previously considered unweldable can now revaluated.
  • 4. WORKING: UMW consists of an ultrasonic generator, which generates a frequency of 20 kHz to 40 kHz from a supply of 220v/50Hz. The converter transforms the high frequency electric energy produced by the generator in to mechanical energy. The booster serves as an amplitude transformer for the required amplitude range as well as a general stabilizer for the oscillations of the transducer system. The sonotrode or horn is the working tool of the ultrasonic metal welding. The pieces to be welded are clamped between the welding tip called sonotrode and anvil. Both tip and anvil are faced with high-speed steel, since considerable wear can occur at the contacting surface. The process of ultrasonic welding is fairly simple. It begins when the parts those are to be welded, such as two multi-strand copper wires for example, are placed together in the welding unit. The system then compresses the wires together with a force of between 50 and several 100 pounds per square inch to form a close connection between the two pieces. Next, the ultrasonic horn is used to vibrate the two pieces together at a rate of around 20000 or 40000 Hz, depending on the application. Before the interaction of the pieces at the interface can be explained, some basic molecular physics must be reviewed. The first principal is that when two clean pieces of metal are placed in intimate contact, they will begin to share electrons, thus welding together, second, at atomic scale even surfaces those that look perfect and smooth are very rough and impure.
  • 5. The majority of these impurities are in the form of metal oxides that were produced when the bare metal was exposed to the atmosphere. The second part of contamination is in the form of ordinary dirt and oils. These impurities form a layer that prevents the electrons in the two parts from passing between them, thus preventing them from welding together. In addition, the rough surface prevents the metals from being in intimate contact, which also prevents the exchange of electrons
  • 6. Ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. It is commonly used for plastics, and especially for joining dissimilar materials. How does ultrasonic soldering work? Instead of chemical agents, surface oxide layers are removed from the soldered surface by using vibrations and a cavitation phenomenon. Ultrasonic soldering technology is different from ultrasonic plastic welding, in which the vibrations generate heat to melt the parts being joined. Principle A high frequency (20 kHz to 40 kHz)ultrasonic vibration is used to join two plastic pieces together. The high frequency vibration generates heat energy at the interface of the two pieces and melts the material How does ultrasonic welding work? How Ultrasonic Welding Works. Ultrasonic welding is an industrial technique whereby high- frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. It is commonly used for plastics, and especially for joining dissimilar materials RF welding (also known as High Frequency (HF) welding or Dielectric welding) is a method of joining thin sheets of polar thermoplastic material together. It uses high frequency (13 to 100 MHz) electromagnetic energy to fuse the materials. A rapidly alternating electric field is set up between two metal welding bars.
  • 7.
  • 8. Ultrasonic Welding Process The ultrasonic welder machine will comprise of components such as – Transducer, Sonotrode and Anvil. The complete welding mechanism will include the following steps: 1. A stationary clamping force is put exactly perpendicular to the interface in between the work pieces. 2. Then the contacting sonotrode of the welder oscillates parallel to the interface. 3. This coalesced effect of stationary and oscillating force generates deformation which furthers welding. Advantages: •It can be applied to miscellaneous combination of material welding and allows welding of thick and thin sections. •Simplified welding of high and heat conduction materials such as copper, gold, aluminum, silver, etc. •he pressures used for welding are low along with low consumption power. •The time taken for welding is less and the width of deformed areas are thinner than that for the cold welding. Disadvantages: •Ultrasonic metal welding needs more power with the work piece as width and hardness increase exponentially. •This welding process is limited to lap joints. •It is dependent on material deformation under tooling. •It might create audible noise from the part resonance.
  • 9. Application: It is mostly used in computer and electrical, aerospace and automotive, medical, and packaging industries. • Computer and Electrical Industries: Here it is used to join wired connections and to create connections in small delicate circuits • Aerospace and Automotive Industry In automotive industries it is used to assemble large plastic and electrical components such as door panels, instrument panels, air ducts, lamps, steering wheels, and upholstery and engine components. In aerospace it is used to join thin sheet gauge and lightweight materials like aluminum. • Medical Industry It does not introduce any contaminants or degradation into the weld. That’s why it is used in medical industries. Items such as anesthesia filters, arterial filters, blood filters, dialysis tubes, pipettes, blood/gas filters, cardiometry reservoirs etc. can be made using ultrasonic welding method. • Packaging Industry It is used to package different materials in food industries. It is used for packaging dangerous materials like explosives, fireworks and chemical.
  • 10. Critical Information / Central Idea of each of the technical papers • 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 ]  Research 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.
  • 11. • The marker material (MM) was a thin foil of pure aluminum 1060 (thickness 0.2 mm),mainly aluminum 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. IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW • 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 means 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.
  • 12. • 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. Statement of the Problem in each of the technical paper
  • 13. Horizontal cross-section with the exit hole at plane z = 2.4mm: (a) FSW ,(b) UVeFSW
  • 14. Various Methods Used in Research Papers • 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 experimental method material is stable flow and no edges and sharp corner seen, So, no need to validate. Sketch map of three-dimensional material flow around the pin: (a) FSW; (b) UVeFSW
  • 15. Typical weld profiles on transverse cross-section: (a) FSW; (b) UVeFSW
  • 16. Key Features of the Technical Research papers • 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. Critical Information / Central Idea of each of the technical papers 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.
  • 17. • 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 US Weld 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.
  • 18. IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW • 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. Title: Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to titanium alloy TiAl6V4
  • 19. Statement of the Problem in each of the technical paper • 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. Various Methods Used in Research Papers • 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. Key Features of the Technical Research papers • 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.
  • 20. • 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. • The foils were examined using a Tenia 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 center of a 25 mm overlap between the sheets when ultrasonic spot welding was performed.
  • 21. Title: Micro-ultrasonic welding using thermoplastic-elastomeric composite film Critical Information / Central Idea of each of the technical papers • 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. • The welding strength of the polymethyl 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. IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW • This present study explores the feasibility of using a composite film made of distributed thermoplastic particles in an elastomeric matrix to restrict the flow of melted energy directors and eliminate problems of trapped air, thus reducing its impact on the shapes off low channels of microfluidic devices. • The design process includes the matrix material selection, energy director distribution and opti-mizing the ultrasonic welding process parameters.
  • 22. • The welding strength of the polymethyl methacrylate (PMMA) and polymethyl siloxane (PDMS) microspheres composite film is up to 35 kPa. • Design of composite film to prevent overflow of PMMA during ultrasonic welding. Statement of the Problem in each of the technical paper • In conventional ultrasonic welding, the energy directors melt and flow across the surface of the samples, resulting in a thinner fusion layer. Various Methods Used in Research Papers • 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 • 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.
  • 23. (a) conventional and (b) composite film ultra-sonic welding Key Features of the Technical Research papers • welding using composite film made of polymethyl 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.
  • 24. • 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 polymethyl 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. Critical Information / Central Idea of each of the technical papers Title: Ultrasonic welding between mild steel sheet and Al-Mg alloy sheet • 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.
  • 25. IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW • 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 Statement of the Problem in each of the technical 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.
  • 26. Various Methods Used in Research Papers • 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
  • 27. Relation between tensile load of a joint welded using an insert metal and clamping force
  • 28. Key Features of the Technical Research papers • 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 Critical Information / Central Idea of each of the technical papers Title: Modeling the effects of ultrasonic vibration on friction stir welding • 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.
  • 29. • 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.
  • 30. IDENTIFIED THE RESEARCH GAP & KNOWLEDGE OF LITERATURE REVIEW • 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 temperature 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-viscosity region 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.
  • 31. • 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. Title: Material flow in ultrasonic vibration enhanced friction stir welding Statement of the Problem in each of the technical 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. Various Methods Used in Research Papers • 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.
  • 32. Unit: kg-m'-s 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).
  • 33. (a) the top surface of (b) the work piece (b) The transverse cross-section
  • 34. Key Features of the Technical Research papers • 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.
  • 35. • 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.
  • 36. Title: Literature Review Sr. No. Paper Title Journal Publisher Year of Publication 1 Material flow in ultrasonic vibration enhanced friction stir welding Journal of Materials Processing Technology ELSEVIER 2015 2 Dissimilar ultrasonic spot welding of aerospace aluminum alloyAA2139 to titanium alloy TiAl6V4 Journal of Materials Processing Technology ELSEVIER 2016 3 Micro-ultrasonic welding using thermoplastic-elastomeric composite film Journal of Materials Processing Technology ELSEVIER 2016 4 Ultrasonic welding between mild steel sheet and Al–Mg alloy sheet Journal of Materials Processing Technology ELSEVIER 2009 5 Modeling the effects of ultrasonic vibration on friction stir welding Journal of Materials Processing Technology ELSEVIER 2015
  • 37. References: C.Q. Zhanga,b, J.D. Robsona, P.B. Prangnellaa, Dissimilar ultrasonic spot welding of aerospace aluminum alloyAA2139 to titanium alloy TiAl6V4, Journal of Materials Processing Technology 231 (2016) 382–388 Amini, S., Amiri, M.R., 2014. Study of ultrasonic vibrations’ effect on friction stir welding. Int. J. Adv. Manuf. Technol. 73, 127–135. Wei Xuan Chana,b, Sum Huan Ngb, King Ho Holden Lia, Woo-Tae Parkc, Yong-Jin Yoona, Micro-ultrasonic welding using thermoplastic-elastomeric composite film, Journal of Materials Processing Technology 236 (2016) 183–188 Amini, S., Amiri, M.R., 2014. Study of ultrasonic vibrations’ effect on friction stir welding. Int. J. Adv. Manuf. Technol. 73 (1–4), 127–135. Lee, T., Lakes, R.S., Lal, A., 2000. Resonant ultrasound spectroscopy for measurementof mechanical damping: comparison with broadband viscoelastic spectroscopy.Rev. Sci. Instrum. 71 (7), 2855–2861. Nandan, R., DebRoy, T., Bhadeshia, H.K.D.H., 2008. Recent advances in friction-stir welding–process, weldment structure and properties. Prog. Mater. Sci. 53, 980–1023.
  • 38. L. Shia, C.S. Wua, X.C. Liua, Modeling the effects of ultrasonic vibration on friction stir welding, Journal of Materials Processing Technology 222 (2015) 91–102 Takehiko Watanabe, Hideo Sakuyama, Atsushi Yanagisawa, Ultrasonic welding between mild steel sheet and Al–Mg alloy sheet, Journal of Materials Processing Technology 209 (2009) 5475–5480 X.C. Liu, C.S. Wu, Material flow in ultrasonic vibration enhanced friction stir welding, Journal of Materials Processing Technology 225 (2015) 32–44