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228 pages

Bond Formation in Ultrasonically Welded Aluminum Sheet Metal

2007

Ultrasonic welding (USW), a solid state joining technology, has been used to bond aluminum alloys commonly used in the automotive industry.

Publisher: ProQuest

About this book
Ultrasonic welding (USW), a solid state joining technology, has been used to bond aluminum alloys commonly used in the automotive industry. Bonding occurs due to USW's high frequency (∼20 kHz) in-plane vibration of sample interfaces while being held under moderate clamp pressure normal to the plane of vibration. Vibration and clamp pressure are transmitted into bond formation via contact with a weld-tip. To better understand how weld-tip geometry affected bond formation, experiments were conducted to quantify how tip geometry influenced plastic deformation characteristics between fully welded coupons of 0.9mm thick AA6111-T4 aluminum alloy. Weld-interface microstructure features were documented by optical microscopy and features quantified in a 19 point matrix. Correlation between microstructure features, such as rolling-wakes, and resulting weld bond strengths of more than 3.0kN is made. Weld zone microstructure features appear to result from deformation at and severe migration of the original weld interface during USW. To confirm this hypothesis, intrinsic and extrinsic markers were employed to monitor weld interface deformation characteristics. Various physical and analytical techniques were used in conjunction with these markers to show that joining of "like" and "dislike" aluminum samples is achieved through mechanical mixing of mating interfaces and not by elemental diffusion. It is also hypothesized that severe deformation of the original interface would result in areas of high residual strain within a formed weld zone. To investigate this and the influence that tip geometry may have on residual strain, fully welded samples were annealed at 500°C for a controlled period of time and recovery, recrystallization and grain growth characteristics were monitored. In all welds, initial recrystallization and grain growth occurred at the outer ends of weld zones and along weld interfaces where the most turbulent mixing and grain size reduction was observed. Similarity in how all welds responded to annealing indicates that the tip geometries investigated had little influence on resulting weld formation. This claim is further supported by lap-shear failure load data for welds made with these tips being within statistical error of each other.



143 pages

Sheet Metal Handbook

Creator: Sue Fournier | Transportation - 1989

... characteristics. Let's examine the four types of aluminum sheet most commonly used. ... Work-hardening is a term used to describe how metal becomes harder and stronger as it is being cold- worked — formed while cold. When an alloy ...

Publisher: Penguin

About this book
Imagine transforming a flat sheet of aluminum alloy into an attractive hood scoop. Or designing and making your won aluminum wheel tubs, floorpan and dashboard for your street machine. How about learning to design and build your own body panels, manifolds, brackets and fuel tanks? These are just a few of the many tips and techniques shared by master metal craftsman Ron Fournier.


Sheet Metal Fabrication

Creator: Eddie Paul |

For instance, if used in sheet form, as in the body metal for a car or motorcycle, 1000-series is great for forming using a sandbag and ... In fact, this is the alloy of choice for most metalworkers if aluminum is the metal they are using for a project.


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