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Mechanisms of Joint Formation in Ultrasonic Spot Welding Aluminium Automotive Sheet
D. Bakavos, Y-C Chen and P. B. Prangnell,
In: TMS - Supplemental Proceedings: Volume I: Materials Processing and Energy Materials: TMS - Symposium, USW of Light Weight Structures; 27 Feb 2011-03 Mar 2011; San Diego . Warrendale, PA: TMS; 2011. p. 735-742.
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Abstract
High power ultrasonic spot welding (HP-USW) is an extremely efficient new method for welding Al alloys, using ~ 2% of the energy of resistance spot welding (RSW). The overall objective of this work was to improve the current poor understanding of the mechanisms of weld formation, when HP-USW is applied to aluminium automotive sheet. To this end, results are reported where we have studied the material flow, combined with, X-ray tomography, and electron microscopy, to characterise the weld defects, stages of weld formation, and microstructure evolution, as a function of welding energy, for a standard automotive material AA6111-T4 (0.92 mm thick sheet). The origin of the complex flow features, seen in HP-USW, are discussed and were found to occur on three characteristic length scales.