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1973 Joint Formation in Ultrasonic Welding Compared With Fretting Phenomena For Aluminium
1973 Joint Formation in Ultrasonic Welding Compared With Fretting Phenomena For Aluminium
1973 Joint Formation in Ultrasonic Welding Compared With Fretting Phenomena For Aluminium
3 Joint formation in ultrasonic welding compared with fretting phenomena for aluminium
Joints between aluminium sheets have been formed using two different processes. The
first process is ultrasonic welding using a vibration frequency of 20kHz. The second
process is fretting where two sheets are clamped together and an oscillatory relative
movement of small amplitude is applied to them. The frequency is 30Hz and the
amplitude is 5 ,um. After a certain number of vibrations a strong joint is formed
between the sheets. The following parameters were chosen to be equal for both
processes: the amplitude of the relative movement in the contact plane, the contact
pressure and the number of vibration cycles. The joints obtained from both processes
were examined using tensile shear tests, scanning electron microscopy and metallographic
sectioning. We conclude that both types of joints are very similar and consequently
formed by the same mechanism. It follows that joint formation in ultrasonic welding
and in fretting of aluminium must be ascribed to plastic deformation of an interfacial
layer. (In our case about 30 ,um thick). Diffusion and recrystallization do not play
an important role.
Introduction followed cycle after cycle . The growth of the joint can
be studied easily this way .
~ to the joint formation in ultrasonic metal welding no
~ nerall y accepted theory exists. A number of possible b) During frettin g no gross temperature rise occurs, sothat
basic mechanisms, which are mentioned in the literature , melting, diffusion and recrystallization cannot play a role.
are reviewed in the next Section.
ln our experiments the joints formed during the first stage
Fretting occurs between con tacting metal surfaces which of the fretting process were not broken because of the
undergo small oscillatory relative displacements. The relatively low amplitude and the small number of cycles.
firs t stage of fretting i.e. , the formati on of j unc tions The word ' fretting' is connected with the formation of wear
(microwelds) seems to be analogous to ultraso nic metal debris (second stage offretting). We, h owever, use 'fretting'
welding. The main difference is the lower vibration fr e- in the sense of 'the first stage of fretting using relatively
quency of the fretting process, which is roughly x 1000 small amplitudes and few cycles'. (This type of joint
lower than the frequency of the ultrasonic we lding process. formation could b e called 'subsonic welding'.)
To verify this analogy we made ultrasonic welds in aluminium Ultrasonic joining
and compared them with aluminium joints obtained by
In ultrasonic metal welding the parts to be welded are
fretting. The parameters (pressure in the contact plane,
clamped bet wee n a 'so notrode' and an anvil (Fig. 1). The
relative vibration amplitude in the contact plane and
'sonotrode' vibrates pa rallel to the interface of the two
number of vibration cycles) were chosen to be almost equal
parts and after a certain time a joint is formed .
in both the ultrasonic welding and fretting experiments.
The aim of the comparison was to inves tigate the mechanism The frequency of vibration is generally between 15 and
of joint formatipn in ultrasonic welding of aluminium. 100kHz. The vibration amplitude of the 'sonotrode' can
range up to 30 ,urn. The bonding time depends upon
For the study of joint formation the fretting process has
rna terial properties and lies between 0.1 s. and 1 s. The
several advantages:
clamping force is so chosen that the pressure in the interface
a) Because of the low frequency the process can be is about 0.3 times the tensile strength of the material.
Table 1
Maximum temperatures observed during ultrasonic bonding of different materials
lower sheet 1 mm 2 mm
Fig. 3a Scanning el ectron mi crograph of a peeled Fig . 4 a Scanning electron micrograph of a peeled joint
ultrasoni c bond in aluminium . Direct ion of observation obtain ed by fretting. Direction of observation perpendi
perpendicular to the joint interface. cular to the joint interface.
Fig. 3b Scanning electron micrograph of a peeled ultra- Fig. 4b Scanning electron micrograp h of a peeled joint
sonic bond in aluminium. obtain ed by fretting.
.. . . .......
- -~
'~
.........
.. .. ., -.
.. -
. .. . -~ -
: -~ . .
-:-, ... -._:_. ; . -- ' :
.. . .. --.
..
"':
-
:
-~
.
.
..~.... .. . . ~ .-...-.--. - . : ....... -- .. . - .'
~.
~
.
....- .; - .-~ ,. --..:-:~: :.. ..:.=---::::::.. . .... ._
. -
. - .. "!" . - .
.- . ' ..
..
.,.
..... -
_,.
.-... .. - - .....,
_
... : :
___: .
~ _':"
"'-;..~~a .
-
--J , .... ... _ ..
........... ~
~ . _:
:_.~ :: - - .
- . ._-..;.
-. :
'a: , .
.... .. .. .
---
-
.-.;.
-- . . .-
"",;
-i. -
- - -
' ....
-. ....
-...
- -~ - ..:
50~
... so..u-,
......
.. .I
. . .
.~
. .-
Fig . 5a . Metallographic section of an ultrasonic bond in Fig. 6a Section of a joint obtained by fretting. As Fig. 5a.
aluminium.
Direction of sectioning parall el to th e vibration directio n
during joining.
Oberved using unpolarized light.
'-....... Region at th e periphery of the joint.
Fig .Sb Sect ion of an ultrasonic bond . Fi g. 6b Sect io n of a jo int obta in ed by fretting. As Fi <J ~il.
Direc tion of sect io ning as Fig. 5a.
Observed using crossed po lari zers .
Same reg ion as in Fig. 5a .
..
. .... _.
. .-...
..
~ 0
..... . .-_,; .
. . .~
-
-
-~- .
...
..
-- -._.: . .
--. ~" .. :. .
~ -: ~
- ~. .. -
_... _. ._
: .... <- . ~- --
- -~
.--... _::
....--.... . ..---.-: .. . ............. ~
~ ,_,. .
. - ... . :.. - - -:
... - -
__ ._,.
..
b
.. : .:. -
- .:;::J--
. -- ... .......
. .
.:. , .
50 A-
-- .
. :. ~
_.. _ . . -
Fig. 5c Section of an ultraso nic bond. Fig. 6c Section of a j o int obta in ed by fretting . A s Fi g. 5c
Direction of sectioning as Fig. 5a.
Observed us i ng un po lari zed light.
Regio n in t he central part of the joint .
I
48 Ultrason ics Intern ational 1973 Conference Proceedings
j
2.3 Joint formation in ultrasonic welding com pared wilh fre tting phenomena for aluminium
Fig . 5d Section of an ultrasonic bond. Direction of sec- Fig . 6d Section of a joint obtained by fretting. As Fig. 5d
tioning as Fig . 5a . Ob se rv ed using crossed polarizers.
Same region as in Fig. 5c.
Fi g. 5e Sect ion o f an u l traso ni c hond. Fiq 6e Sec t ion o f a jo i nt ob t ained by fretting. As Fig . 5e .
D irect io n of sect iorlrrHJ pc rpcnd icular to th e vibrati on
dire ct ion ck11inu io ini r1g
Obse rved usi n~ cross>'d po l;11i ze rs. he:11 \(IL'II;,"IIi , tiJ , e'.\l'lcilc.l' ,,J '''["":'. J, ,, n,kd a reas in
R e~ti on in the central p;crt o f th e ioi111 . '"' ''' tvp'' -" j11i11h :111<1 1l ' ,r,,, .. ,, <ipl:~, t ic":illy deform ed
ll l lc' rlac cs i11 t!tc scc tiu ns. tlut tile ft1111l atinn o f joints in
tiltr~1 Sn11 i r weldini:! :111d d uri n\! tile l'ir\1 s i ~ I \!C t' f fre ttin g
oblo ng in the: dirclli'll uf tile' llll'VL'IIIc rlt (l : ig. 4a and Fig. 7).
c':lll he ,i,c'llllcd [II tile \:lll lc' .. ,,,, .!111,111.
Remuval <lillie ,1;'! ,l. r\ er ",,ur-; 'lliJiili,IIH.' UUSiy wi th the
i!rnw tlt "~'tir e' h"11' 1' \ 'tire' l''''cc'" c ~>t ll illues Jn inc rea sin g lkc-.111,,. "' tliL' !"11 (' 11 \\'l'i : 1 'I tiJ , frc'l lillg e xpe ri-::lCI\ 1
lllllllher "!' J-," " d' _., ,,,c. lllllle'\i , le'~J <.:c lr1 this manne r th e LthiiUI I~ ill \\ in the I'IC\c'! '[ c'\fll'lll lle'llh) . gross tempcr:tlurc
pi~JS t ic~illl del."ilile'cl lliie'JI ~IC I ~il l.ryer I'> C.\tl' lllied an d th e ri :;c dues 11"1 urcu r in frct t;n~ . Su temperatu re effec ts
j 11 iIIi i-; I.e> lllle'ti <:: t: IJ ~'' dillu'>i,ll l ~111d r-cc11 ''JJ iinli "ti .: :~r1 c' \Cr t lit tle
ttilluc nLc u1t thi s pmcc ss . T it ~. onilpuss ib le mec hani sm
Th e bonded ~ r rc ~1s ~ , ,,,,. l,,,, ar ds :1 lc n<z llt ,, f seve ral hundreds
'''' j11 ittl fJJIJ I:Ili u n under t~ti; c" ndi tl n is pL1stic defo rm Jti .1 :1
uf llliL'!'<llll"l''' ( 1- i~s t dtld 7 ) ~Jtld l'in-.ilh l':trt ly ove rl ap . The
as a lr cadv dcscrtbcd.
l::trge r the sl tp a tllplituJ, the l'ii slcr tl1 c gruwtl r. Fretting
c.\p criJIIct lts with an ~unp litu de "f ~U /1111 a nd 200 vi b ra ti on I lie": ct>tl> tde l:tli u ns k :1d t 'ill t'ina l cilllc"l us io n : Joint
eydcs yidd.t c> itll'> l'.tt lt the sa me streng th as the joints J,,,,lu ti<JII 11 1 ult r:JSullic' ll'l'e:111g 'I :illl111illiu111 is caused by
rnull i<mcJ in I .tbk ~I ~ 000 cyLIcs: 5 f1111 ) . pLi.,ltc dchr!JJ:ili"li.
After '>elcnl tl li ' ll\~!rld> "' c\ _lc, II'JtiJ ~111 :llnpli t ude o f 5 fl nl 11 tJ, '"" !. ,,,_.c lll ~ 11 tit : !''.,,., __:11!1 ,k k rme d as pe riti es .
tk,tn!c'liiJIJ "' ti" llcJ,i bc'i!ilh :11 'tile' J'crq>ll cry ( figs 7c a nd d). llltcle' >ill l:icc IJ1e'f\ ~Ill.? 1'1 ,:,. c!h;lc'l,..;d :tn d adhesion
rile Llr:,:c l the: .l:!!plit:.!c'c' ti lL' l,i )lc r tltc destnlct io n. "C: -.''11' . , lie'"' Slli, rli h" 1Hh ~! '''- 11 1 tile dirclt io n o f th e
\i brj ttnv lllOVc' tJW nt. In tlih i.1a1 tire ll'iJole area is weld ed
Compar iso n of the res ults and c o nclus i o n :ilt,' r a c.c rt :ri n num be r of vibut1 u ns and J pl astically de-
Th e resul ts of the tensile sltea r tes ts exa minat ion with the t\ rn Jcd interL1c Ld i:J ycr , 11 itil J tltic:l-.n.css o l' abo ut 30 j.1m ,
scan ni ng ckctmn ln icrusc,Jpc :tnJ rncta ll ug ra ph.ic sec tioning comes into existence. T cm;>ciJturc- ciTecrs such as diffusio n
show~~ strik ing simi!:tit '- b.' tllc'L' Il ultrC~sonic joints and anJ rec rys t:tl!itJ ti on do nut !'b\ J rok in this process. They
l'rctted j<Jints. usi ng :di'lllSt cqu:il p:1ra!nctns in bo th pro- c::lll uccu r d u rin g ultraso ni l' 1:elding but do nut primaril y
ct'ss~.'s . l t is _. ,,11:i .. c.: '":" ..... c: quality uf the tensile ,ausc the furm:tt io n of t he j,_,inr.
J. L. Hart/zoom
Fi g. 7 Scanning elect ron m icrographs of jo i nts obtained by fr etting of pol ish ed specimens. Vibration ampli t ude and pressure
as in T able 2.
-\i n bin ckr. S.Ll. a nd Tikh nrn ir <'v: t. 1-.f-:. Tile mechanism wher eb y I I) (, c:ns c:n~ . 1-I.T .. -\ cbtm . .I. A. Shi u'''-' Shi rl. On so me fundam e nta l
_i,>ints arc i"urmcd in u l t r :J su JJiewdd i n~. lt'elding Production , 9 l '~" bkrn s in ultr,Json ic weld in ~ r~f d i'S ir ni Ltr nwuls . Weldi11g
t 1962) , pp. 61-65 . .fuum al. 46 . (1 967 ). pp . 145-153.
l 'ri sc ll , J ., I'I:Jd zc r, I'. I '. aml C lw1 ~ . U.l. Ult ra so nic welding of I! Sil in . I .. L .. Kuznct sn v. V. A . cr nd S,su lin . G.\. The ultrasoni c
md ah in v:tcuunl II th 'lTD H. Co nl'crcn cc held at the Uni ve rsity \\ , ldin~ r>f crlu rn iniu m a nd its :til, ,-, _ li'cldinu p;,xfuct ion 3
" f \I:Jn chc"cr. 14-1 8 Sc't'i .. ( 197 0 ). Pc r ~a m o n Press, (197 0) . (l 960 ). pp. l 9-25. . ,, ,
\\'ca re , N.E., Ant o nuvi ch . .1.:\. and :\ l unr uL', ICE . Fundamen ta l I~ B.t l tndi n . C. F. :tncl Sil1i n . 1.. 1.. !'he r~>k ,, 1- fr ictio n in ultra sonic
st udies o f ultra s<~ nic 1\'C ldin~ . lt'd ding .lrm mal. 39, (1960), 1\"c-ld ing l ;ves t ycJ ,-\\i SSSR . OT :\ . .11<-ra//urgl' en d ji1el, 6, (19 60).
PI' 331-341.
I_; IJ.,,Lrrhllll . ( .. 1 . .Jncl Sill 111. l...L. \k r!J, ,d, r,, ,. ubr ain ing stea d y
-1 J" ne.s . .1. 13 ., \Jar,> pis. :\ .. l"h o n1 as . .I. G. an d Ba ncr o ft , D. Pheno- conditio ns in th e cd trctSillli c 1\'c l clin ~ , >I JllC ia h. l\'c/ding
t ncno lu ~ i cal cunsidcratiun s in ultraso nic w c l clin~, hie/ding /l o,/uctio n. 12. (l96l).pp. 19 .
.lo umal. 40. (1961). pp. 3- 19.
l -1 m..,d .r \1 .. Shin. S.. \ liycr_c! i, .\1. a nd \Li tsuda . H. Joint m echan-
O l's han skii. N . A . Th e fortnat ion of ;oints in the ultrasonic i, tn ,,; ul traso ni c \\e lcli n_c!. Tr a ns"uiuns o f th e hpa nese Inst i
1\ddi n:,: of meta ls. Auromaric J~'elding . 14, (1 96 1), No . 3, lu te ut ,\ lda ls, 4 , (1963) , pp. 250 25 6.
pp. 1-8 . 15 Ginzburg. S.K., \litskevi clt , A.~l. and Nosov . Y u.G. Formati on
of th e jo int in ultrason ic welclin)! . IJ'c/din !( Prn ,Juct ion 14 3
6 Ri ch ter, H. Ubcr untcr suchun~c n vo n Vo rgangc n beim Verbinden ( I 96 7l. pp 83 -R7 . , ' ,
mcta.llische r We rksto ffe dur ch UltraschaJI. Sclnveissen und
Schneiden. 22. Heft 2, (19 70), p p. 70 -73. 16 Joshi . K.C. Th e fo rt m t ion of ul t rchll!li ,- bun ds b ~rwee n metal s,