Hostname: page-component-586b7cd67f-rcrh6 Total loading time: 0 Render date: 2024-11-28T15:11:05.505Z Has data issue: false hasContentIssue false
  • English
  • Français

Modelling and Characterization of Ultrasonic Consolidation Process of Aluminium Alloys

Published online by Cambridge University Press:  01 February 2011

Elaheh Ghassemieh  and
Elaheh Ghassemieh
Elaheh Ghassemieh
Affiliation:
[email protected], University of Sheffied, Mechanical Engineering, Mappin Street, Sheffield, S1 3JD, United Kingdom, 44(0)114-2227868
Elaheh Ghassemieh
Affiliation:
[email protected], University of Sheffield, Mechanical Engineering, Mappin street, Sheffield, S1 3JD, United Kingdom
Get access

Abstract

Ultrasonic consolidation process is a rapid manufacturing process used to join thin layers of metal at low temperatures and low energy consumption. In this work, finite element method has been used to simulate the ultrasonic consolidation of Aluminium alloys 6061 (AA-6061) and 3003 (AA-3003). A thermomechanical material model has been developed in the framework of continuum cyclic plasticity theory which takes into account both volume (acoustic softening) and surface (thermal softening due to friction) effects. A friction model based on experimental studies has been developed, which takes into account the dependence of coefficient of friction upon contact pressure, amount of slip, temperature and number of cycles. Using the developed material and friction model ultrasonic consolidation process has been simulated for various combinations of process parameters involved. Experimental observations are explained on the basis of the results obtained in the present study. The current research provides the opportunity to explain the differences of the behaviour of AA-6061 and AA-3003 during the ultrasonic consolidation process. Finally, trends of the experimentally measured fracture energies of the bonded specimen are compared to the predicted friction work at the weld interface resulted from the simulation at similar process condition. Similarity of the trends indicates the validity of the developed model in its predictive capability of the process.

Keywords

weldingcompositesimulation
Type
Research Article
Information
MRS Online Proceedings Library (OPL) , Volume 1079: Symposium N – Materials and Processes for Advanced Interconnects for Microelectronics , 2008 , 1079-N09-05
Copyright
Copyright © Materials Research Society 2008

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

1. Joshi, K.C., The formation of ultrasonic bonds between metals. Welding Journal, 1971. 50: p. 840–848.Google Scholar
2. Kong, C.Y., Investigation of Ultrasonic consolidation for embedding active/passive fibres in aluminium matrices, in Rapid Manufacturing Center. 2005, Loughborough University: Loughborough, UK. p. 1–207.Google Scholar
3. Kong, C.Y., Soar, R.C., and Dickens, P.M., Characterisation of aluminium alloy 6061 for the ultrasonic consolidation process. Materials Science and Engineering A, 2003. 360: p. 99–106.Google Scholar
4. Kong, C.Y., Soar, R.C., and Dickens, P.M., Optimum process parameters for ultrasonic consolidation of 3003 aluminium. Journal of Materials Processing Technology, 2004. 146: p. 181–187.Google Scholar
5. Krzanowski, J.E., A Transmission Electron Microscopy Study of Ultrasonic Wire Bonding. IEEE Trans. CHMT, 1990. 13: p. 176–181.Google Scholar
6. Tucker, J.C., Ultrasonic welding of copper to laminate circuit board, in Materials Science & Engineering. 2002, Worcester Polytechnic Institute. p. 125.Google Scholar
7. Doumanidis, C. and Gao, Y., Mechanical Modelling of Ultrasonic Welding. Welding Journal, 2004. 4: p. 140–146.Google Scholar
8. Chaboche, J.L., Time independent constitutive theories for cyclic plasticity. International Journal of Plasticity, 1986. 5: p. 247–302.Google Scholar
9. Chaboche, J.L., Constitutive equations for cyclic plasticity and cyclic viscoplasticity. International Journal of Plasticity, 1989. 5: p. 247–302.Google Scholar
10. ABAQUS, ABAQUS version 6.5, Online Documentation. 2006, Hibbit & Karlsson.Google Scholar
11. Cheng, X. and Li, X., Investigation of heat generation in ultrasonic metal welding using micro sensor arrays. J. Micromechanics and microengineering, 2007. 17(2): p. 273–282.Google Scholar
12. Li, D., Defining Optimum Parameters for Embedding SiC fibres and influence on bond strength in Al 6061 matrix. 2007, Rapid Manufacturing Research Group, Loughborough University: Loughborough, UK. p. 1–19.Google Scholar
13. Li, D., Report for machine performance validation through comparison of peel strength and linear weld density of samples made before and after machine maintenance. 2007, Rapid Manufacturing Research Group, Loughborough University: Loughborough. p. 1–14.Google Scholar
14. Davis, J. R., ASM specialty handbook: Aluminium and aluminium aloys. 1993 ASM international Ohio.Google Scholar
15. Kaufman, J. G., Properties of Aluminium Alloys: Tensile, Creep, and Fatigue Data at High and Low Temperatures, 1999 ASM, Metals Park, OH 44073–0002, USA.Google Scholar
16. Hopperstad, O. S., Langseth, M., Remseth, S., Cyclic stress-strain behaviour of Alloy AA6060, Parth I: Uniaxial experiments and modeling. Int. J. Plasticity, 1995. 11: p. 725–739.Google Scholar
17. Naidu, N. K. R, and Raman, S. G. S., Effect of contact pressure on fretting fatigue behaviour of Al-Mg-Si alloy. International Journal of Fatigue, 2005. 27: p. 283–291.Google Scholar
18. Zhang, C. B., Zhu, X. J., and Li, L. J., A study of friction behaviour in ultrasonic welding (consolidation) of aluminium. AWS Conference: Session 7: Friction and resistance welding/materials bonding process, 2006.Google Scholar