Mechanisms of joint and microstructure formation in high power ultrasonic spot welding 6111 aluminium automotive sheet

Resistance spot welding (RSW) is difficult to apply to aluminium automotive alloys. High power ultrasonic spot welding (HP-USW) is a new alternative method which is extremely efficient, using ∼2% of the energy of RSW. However, to date there have been few studies of the mechanisms of bond formation a...

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Bibliographic Details
Published in:Materials science & engineering. A, Structural materials : properties, microstructure and processing Structural materials : properties, microstructure and processing, 2010-09, Vol.527 (23), p.6320-6334
Main Authors: Bakavos, D., Prangnell, P.B.
Format: Article
Language:English
Subjects:
AA6111
Alloys
Aluminium
Aluminum base alloys
Applications
Applied sciences
Automotive components
Automotive engineering
Energy use
Engineering techniques in metallurgy. Applications. Other aspects
Exact sciences and technology
Flow features
Joining, thermal cutting: metallurgical aspects
Lap shear strength
Metals. Metallurgy
Microbonding
Microstructure
Spot welding
Tomography
Ultrasonic welding
Weight reduction
Welded joints
Welding
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Summary:Resistance spot welding (RSW) is difficult to apply to aluminium automotive alloys. High power ultrasonic spot welding (HP-USW) is a new alternative method which is extremely efficient, using ∼2% of the energy of RSW. However, to date there have been few studies of the mechanisms of bond formation and the material interactions that take place with this process. Here, we report on a detailed investigation where we have used X-ray tomography, high resolution SEM, and EBSD, and dissimilar alloy welds, to track the interface position and characterise the stages of weld formation, and microstructure evolution, as a function of welding energy. Under optimum conditions high quality welds are produced, showing few defects. Welding proceeds by the development and spread of microwelds, until extensive plastic deformation occurs within the weld zone, where the temperature reaches ∼380 °C. The origin of the weld interface ‘flow features’ characteristic of HP-USW are discussed.
ISSN:0921-5093
1873-4936
DOI:10.1016/j.msea.2010.06.038