Ultrasonic welding is attracting increasing attentions in lithium battery joining in the field of battery electric vehicle manufacturing. A three-dimensional finite element model was constructed to study the temperature distribution and heat generation in ultrasonic welding process. Numerical analysis showed that heat generation from plastic deformation accounts for nearly a quarter of the whole heat generation (material plastic deformation and interface friction). The fraction changes little with different sequence of specimens. The highest temperature locates at the contact interface of specimens and it is much lower than the melting point of the joining materials. Temperature distribution of the structure is not symmetric, and there are abnormal points under the effect of serrated ridges of sonotrode tip. Welding process can be divided in to three periods based on temperature evolution on the contact interface of lower specimen. The proposed model is validated by comparing simulated temperature evolution with experimental result.
JianC., WeiZ., LiF. Z., , ‘Determination of thermal contact conductance between thin metal sheets of battery tabs’, Int. J. Heat Mass Transfer, 2014, 69, 473–480.
2.
HeideB. M., JuliaD., BenediktL., , ‘A review of current automotive battery technology and future prospects’, P.I. Mech. Eng. D-J. Automobile Eng., 2013, 227–761.
3.
LeeS. S., KimT. H., HuS. J., , ‘A state-of-the-art review on lithium-ion battery joining, assembly and packaging in battery electric vehicles’, The 25th World Battery, Hybrid and Fuel Cell Electric Vehicle Symposium and Exhibition, Shenzhen, China, 2010, Nov., 5–9.
4.
QiuR., IwamotoC. and SatonakaS.: ‘Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate’, J. Mater. Process. Technol., 2009, 209, (8), 4186–4193.
5.
RobsonJ., PanteliA. and PrangnellP. B.: ‘Modelling intermetallic phase formation in dissimilar metal ultrasonic welding of aluminium and magnesium alloys’, Sci. Technol. Weld. Join., 2012, 17, (6), 447–453.
6.
PatelV. K., BholeS. D. and ChenD. L.: ‘Microstructure and mechanical properties of dissimilar welded Mg2Al joints by ultrasonic spot welding technique’, Sci. Technol. Weld. Join., 2012, 17, (3), 202–206.
7.
KimT. H., YumJ., HuS. J., SpicerJ. P. and AbellJ. A.: ‘Process robustness of single lap ultrasonic welding of thin, dissimilar materials’, CIRP Ann. Manuf. Technol., 2011, 60, 17–20.
8.
HazlettT. H. and AmbekarS. M.: ‘Additional studies on interface temperatures and bonding mechanisms of ultrasonic welds’, Weld. J., 1970, 50, (5), 196s–200s.
9.
PatelV. K., BholeS. D. and ChenD. L.: ‘Improving weld strength of magnesium to aluminium dissimilar joints via tin interlayer during ultrasonic spot welding’, Sci. Technol. Weld. Join., 2012, 17, (5), 342–347.
10.
KoellhofferS., GillespieJ. W., AdvaniS. G. and BogettiT. A.: ‘Role of friction on the thermal development in ultrasonically consolidated aluminum foils and composites’, J. Mater. Process. Technol., 2011, 211, (11), 1164–1877.
11.
JoshiK. C.: ‘Formation of ultrasonic bonds between metals’, Weld. J., 1971, 50, 840–848.
12.
ZhangC. and LiL.: ‘A coupled thermal-mechanical analysis of ultrasonic bonding mechanism’, Metall. Mater. Trans. B, 2009, 40B, 196–207.
13.
HazlettT. H. and AmbekarS. M.: ‘Additional studies on interface temperatures and bonding mechanisms of ultrasonic welds’, Weld. J., 1970, 49, 196–200.
14.
LiJ., HanL. and ZhongJ.: ‘Short-circuit diffusion of ultrasonic bonding interfaces in microelectronic packaging’, Surf. Interface Anal., 2008, 40, 953–957.
15.
WatanabeA., YanagisawaT. and SunagaS.: ‘Ultrasonic welding of Al–Cu and Al-SUS304—study on the ultrasonic welding of dissimilar metals (1st report)’, Weld. Res., 2000, 46, (2), 1–19.
16.
HazlletT. H. and AmbekarS. M.: ‘Additional studies on interface temperatures and bonding mechanisms of ultrasonic welds’, Weld. J., 1970, 196–200.
17.
GinzburgS. K. and YuNosov G.: ‘Characteristics of diffusion processes in commercial iron during ultrasonic welding’, Met. Sci. Heat Treat., 1967, 9, (4), 306–308.
18.
ChangU. I. and FrischJ.: ‘On optimization of some parameters in ultrasonic metal welding’, Weld. J., 1974, 53, (1), 24–35.
19.
KreyeH.: ‘Melting phenomena in solid state welding processes’, Weld. J., 1977, 56, 154–158.
20.
GunduzI. E., AndoT., ShattuckE., WongP. Y. and DoumanidisC. C.: ‘Enhanced diffusion and phase transformations during ultrasonic welding of zinc and aluminium’, Scr. Mater., 2005, 52, 939–943.
21.
KellyG. S., AdvaniS. G., GillespieJ. W., , ‘A model to characterize acoustic softening during ultrasonic consolidation’, J. Mater. Process. Technol., 2013, 213, 1835–1845.
22.
YangY., Janaki RamG. D. and StuckerB. E.: ‘Bond formation and fiber embedment during ultrasonic consolidation’, J. Mater. Process. Technol., 2009, 209, (10), 4915–4924.
23.
BakavosD. and PrangnellP. B.: ‘Mechanisms of joint and microstructure formation in high power ultrasonic spot welding 6111 aluminium automotive sheet’, Mater. Sci. Eng. A, 2010, 527, 6320–6334.
24.
ZhaoY. Y., LiD. and ZhangY. S.: ‘Effect of welding energy on interface zone of Al–Cu ultrasonic welded joint’, Sci. Technol. Weld. Join., 2013, 18, (4), 354–360.
25.
PrangnellP., HaddadiF. and ChenY. C.: ‘Ultrasonic spot welding of aluminium to steel for automotive applications—microstructure and optimization’, Mater. Sci. Technol., 2011, 27, 616–624.
26.
PatelV. K., BholeS. D. and ChenD. L.: ‘Influence of ultrasonic spot welding on microstructure in a magnesium alloy’, Scr. Mater., 2011, 65, 911–914.
27.
SiddiqA. and GhassemiehE.: ‘Thermomechanical analysis of ultrasonic welding process using thermal and acoustic softening effects’, Mech. Mater., 2008, 40, 982–1000.
28.
SiddiqA. and GhassemiehE.: ‘Theoretical and FE analysis of ultrasonic welding of aluminum alloy 3003’, J. Manuf. Sci. Eng., 2009, 131, 041007-1–041007-11.
29.
de ViresE.: ‘Mechanics and mechanism of ultrasonic metal welding’, PhD thesis, The Ohio State University, OH, USA; 2004.
30.
ElangovanS., SemeerS. and PrakasanK.: ‘Temperature and stress distribution in ultrasonic metal welding an FEA-based study’, J. Mater. Process. Technol., 2009, 209, 1143–1150.
31.
GaoY. and DoumanidisC.: ‘Mechanical analysis of ultrasonic bonding for rapid prototyping’, J. Manuf. Sci. Eng., 2002, 124, 426–434.
32.
DoumanidisC. and GaoY.: ‘Mechanical modeling of ultrasonic welding’, Weld. J., 2004, 83, 140-s–146-s.
33.
LeeD., ElijahK. and CaiW.: ‘Ultrasonic welding simulations of multiple, thin and dissimilar metals for battery joining’, Proceedings of the ASME/ISCIE 2012 International Symposium on Flexible Automation, June 18–20; 2012, St. Louis, MO, USA.
34.
LeeD., ElijahK. and CaiW.: ‘Ultrasonic welding simulations for multiple layers of lithium-ion battery tabs’, Trans. ASME J. Manuf. Sci. Eng., 2013, 135, 061011-1–061011-13.
35.
KimW., ArgentoA., GrimaA., SchollD. and WardS.: ‘Thermo-mechanical analysis of frictional heating in ultrasonic spot welding of aluminium plates’, P.I. Mech. Eng. B-J. Eng. Manuf., 2010, 225, 1093–1103.
GuptaN. K., IqbalM. A. and SekhonG. S.: ‘Experimental and numerical studies on the behavior of aluminum plates subjected to impact by blunt- and hemispherical-nosed projectiles’, Int. J. Impact Eng., 2006, 32, 1921–1944.
38.
JohnsonG. R. and CookW. H.: ‘A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures’, Proc. 7th International Symposium on Ballistics, The Hague, Netherlands, International Ballistics Committee21, 541–547; 1983.
39.
TouloukianY. S., KirbyR. K. and TaylorR. E.: ‘Thermophysical properties of matter’Vol. 12,; 1975, New York, IFI/Plenum.
40.
TouloukianY. S., PowellR. W. and HoC. Y.: ‘Thermophysical properties of matter’Vol. 1,; 1970, New York, IFI/Plenum.
41.
SriramanM., GonserM., FujiiH., BabuS. and BlossM.: ‘Thermal transients during processing of materials by very high power ultrasonic additive manufacturing’, J. Mater. Process. Technol., 2011, 211, 1650–1657.
