Title: An experimental investigation on joining of aluminium with steel using ultrasonic metal welding

Authors: Mantra Prasad Satpathy; Susanta Kumar Sahoo

Addresses: Department of Mechanical Engineering, National Institute of Technology Rourkela, Pin-769008, Odisha, India ' Department of Mechanical Engineering, National Institute of Technology Rourkela, Pin-769008, Odisha, India

Abstract: This paper presents some preliminary results in ultrasonic joining of ferrous and non-ferrous metals, which has recently been adopted to manufacture micro-welded parts. The effects of ultrasonic welding parameters such as vibration amplitude, weld time and weld pressure were compared through tensile shear and T-peel tests with microstructural analysis. These mechanical tests revealed that the maximum weld strength was obtained at the highest vibration amplitude. The temperature generated at the weld zone is lower than the aluminium melting temperature, which is consistent with solid state welding. Microhardness tests were also carried out to show the plastic deformation. The grain deformations, phase transformation, and aluminium diffusion were also examined through SEM and EDS analysis.

Keywords: ultrasonic metal welding; USMW; weld strength; tensile shear test; t-peel test; microhardness; metallographic analysis; ultrasonic joining; aluminium; steel; ferrous metals; non-ferrous metals; vibration amplitude; weld time; weld pressure; ultrasonic welding; microstructure; temperature; plastic deformation; grain deformation; phase transformation; aluminium diffusion.

DOI: 10.1504/IJMMS.2016.082861

International Journal of Mechatronics and Manufacturing Systems, 2016 Vol.9 No.4, pp.299 - 309

Available online: 10 Mar 2017

Full-text access for editors Access for subscribers Purchase this article Comment on this article