Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061
This study investigates the effects of superimposed ultrasonic vibration on resistance spot welding (RSW) of aluminum alloy AA6061-T6. A novel ultrasonically assisted resistance spot welding process, referred to as ultrasonic resistance welding (URW), is applied to weld AA6061 at various conditions...
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2020-07-01
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doaj-40f22afed3704cb1b0d9998cef5777da2020-11-25T02:58:37ZengElsevierMaterials & Design0264-12752020-07-01192108690Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061Umair Shah0Xun Liu1The Ohio State University, EJTC, 1248 Arthur Adams Drive, Columbus, OH 43221, United States of AmericaCorresponding author.; The Ohio State University, EJTC, 1248 Arthur Adams Drive, Columbus, OH 43221, United States of AmericaThis study investigates the effects of superimposed ultrasonic vibration on resistance spot welding (RSW) of aluminum alloy AA6061-T6. A novel ultrasonically assisted resistance spot welding process, referred to as ultrasonic resistance welding (URW), is applied to weld AA6061 at various conditions and compared with the results from RSW. Lap shear tensile tests of URW welds show significantly improved mechanical properties, including higher strength, better ductility and higher amount of energy absorbed prior to failure compared with RSW welds. Optical micrographs of the weld cross section show that the ultrasonic vibration enhances nugget formation and minimizes porosities defects. Besides, equiaxed crystal structure is generally observed in the nugget center of URW welds whereas the majority of RSW fusion zone is dominated with columnar grain structure. In situ thermal imaging of the two processes shows a lower temperature distribution, smaller heating and cooling rates during URW. This is attributed to the ultrasonically assisted fracture and breakdown of surface oxides and contaminates, which reduces the contact resistance and accordingly heat generation rate.http://www.sciencedirect.com/science/article/pii/S0264127520302240Resistance spot weldingPower ultrasonicsAluminum joiningContact resistanceInfrared imaging |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Umair Shah Xun Liu |
spellingShingle |
Umair Shah Xun Liu Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061 Materials & Design Resistance spot welding Power ultrasonics Aluminum joining Contact resistance Infrared imaging |
author_facet |
Umair Shah Xun Liu |
author_sort |
Umair Shah |
title |
Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061 |
title_short |
Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061 |
title_full |
Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061 |
title_fullStr |
Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061 |
title_full_unstemmed |
Effect of ultrasonic energy on the spot weldability of aluminum alloy AA6061 |
title_sort |
effect of ultrasonic energy on the spot weldability of aluminum alloy aa6061 |
publisher |
Elsevier |
series |
Materials & Design |
issn |
0264-1275 |
publishDate |
2020-07-01 |
description |
This study investigates the effects of superimposed ultrasonic vibration on resistance spot welding (RSW) of aluminum alloy AA6061-T6. A novel ultrasonically assisted resistance spot welding process, referred to as ultrasonic resistance welding (URW), is applied to weld AA6061 at various conditions and compared with the results from RSW. Lap shear tensile tests of URW welds show significantly improved mechanical properties, including higher strength, better ductility and higher amount of energy absorbed prior to failure compared with RSW welds. Optical micrographs of the weld cross section show that the ultrasonic vibration enhances nugget formation and minimizes porosities defects. Besides, equiaxed crystal structure is generally observed in the nugget center of URW welds whereas the majority of RSW fusion zone is dominated with columnar grain structure. In situ thermal imaging of the two processes shows a lower temperature distribution, smaller heating and cooling rates during URW. This is attributed to the ultrasonically assisted fracture and breakdown of surface oxides and contaminates, which reduces the contact resistance and accordingly heat generation rate. |
topic |
Resistance spot welding Power ultrasonics Aluminum joining Contact resistance Infrared imaging |
url |
http://www.sciencedirect.com/science/article/pii/S0264127520302240 |
work_keys_str_mv |
AT umairshah effectofultrasonicenergyonthespotweldabilityofaluminumalloyaa6061 AT xunliu effectofultrasonicenergyonthespotweldabilityofaluminumalloyaa6061 |
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