Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding
Ultrasonic metal welding machines are suitable for various complex applications (e.g., battery tabs) through unique mechanical design, special pressure application methods and high-precision welding. This work reports the weldability, forming quality and fractographic analysis of copper multilayered...
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| Format: | Article |
| Language: | English |
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Elsevier
2024-11-01
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| Series: | Alexandria Engineering Journal |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S1110016824008068 |
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| author | Zeshan Abbas Lun Zhao Jianxiong Su Peng Zhang Jianxiong Deng Zeng Jiaqi Vivek Patel Hafiz Abdul Saboor Md Shafiqul Islam |
| author_facet | Zeshan Abbas Lun Zhao Jianxiong Su Peng Zhang Jianxiong Deng Zeng Jiaqi Vivek Patel Hafiz Abdul Saboor Md Shafiqul Islam |
| author_sort | Zeshan Abbas |
| collection | DOAJ |
| description | Ultrasonic metal welding machines are suitable for various complex applications (e.g., battery tabs) through unique mechanical design, special pressure application methods and high-precision welding. This work reports the weldability, forming quality and fractographic analysis of copper multilayered welded joints which were studied by SEM-EDS characterization, micro-hardness testing and tensile testing based on ultrasonic double roller welding (UDRW). Three groups of process parameters (A, B and C) were established to investigate the performance, production quality and welded joint surface interconnections. The tensile testing results of sample under parameter 3 in group A [S-P3(A)] indicate the maximum tensile strength of 69.859 N in T-peel test while the average tensile strength has increased by 58.525 N due to rise in welding time from 2 sec to 5 sec. The results analysis indicates that welding quality features in S-P3(A) joints under 4 bar, 100 mm/s, 45 % have been exploited. The over-welded zone was transformed into good-welded zone. The micro-cracks, fatigue stations and peeling texture in multilayers were reduced. It was found that when the welding energy was 10000 J then the tearing edges and interlayers cracks were minimized while keeping the other parameters constant. Moreover, when the amplitude increased up to 50 %, then numerous micro-cracks and micro-fissure stations were created, which leads to the occurrence of fracture in multi-layer welded joint. The EDS study investigated that the complex features are formed at the interface junction of sample 3 S3(A) in multilayer welds. The complex multilayer microstructures can induce and produce unique hardness properties for battery manufacturing. It leads to high quality and durable welds. Eventually, it is experimentally demonstrated that robust 40 layer welded joints can be obtained by the UDRW process. Data availability: The datasets used and/or analyzed during the current study are available from the corresponding author upon reasonable request. |
| format | Article |
| id | doaj-art-9a1268b96d7d4a07b608588e76e9b71e |
| institution | Kabale University |
| issn | 1110-0168 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Alexandria Engineering Journal |
| spelling | doaj-art-9a1268b96d7d4a07b608588e76e9b71e2024-11-15T06:11:15ZengElsevierAlexandria Engineering Journal1110-01682024-11-01107491506Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller weldingZeshan Abbas0Lun Zhao1Jianxiong Su2Peng Zhang3Jianxiong Deng4Zeng Jiaqi5Vivek Patel6Hafiz Abdul Saboor7Md Shafiqul Islam8Institute of Ultrasonic Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Ultrasonic Technology, Shenzhen Polytechnic University, Shenzhen 518055, China; Corresponding author.Institute of Ultrasonic Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Ultrasonic Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Ultrasonic Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Ultrasonic Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaDepartment of Engineering Science, University West, Trollh ̈attan 46186, SwedenSchool of Mechatronic Engineering and Automation, Shanghai University, Shanghai 200444, ChinaDepartment of Mechanical Engineering, Blekinge Institute of Technology, Karlskrona 37179, SwedenUltrasonic metal welding machines are suitable for various complex applications (e.g., battery tabs) through unique mechanical design, special pressure application methods and high-precision welding. This work reports the weldability, forming quality and fractographic analysis of copper multilayered welded joints which were studied by SEM-EDS characterization, micro-hardness testing and tensile testing based on ultrasonic double roller welding (UDRW). Three groups of process parameters (A, B and C) were established to investigate the performance, production quality and welded joint surface interconnections. The tensile testing results of sample under parameter 3 in group A [S-P3(A)] indicate the maximum tensile strength of 69.859 N in T-peel test while the average tensile strength has increased by 58.525 N due to rise in welding time from 2 sec to 5 sec. The results analysis indicates that welding quality features in S-P3(A) joints under 4 bar, 100 mm/s, 45 % have been exploited. The over-welded zone was transformed into good-welded zone. The micro-cracks, fatigue stations and peeling texture in multilayers were reduced. It was found that when the welding energy was 10000 J then the tearing edges and interlayers cracks were minimized while keeping the other parameters constant. Moreover, when the amplitude increased up to 50 %, then numerous micro-cracks and micro-fissure stations were created, which leads to the occurrence of fracture in multi-layer welded joint. The EDS study investigated that the complex features are formed at the interface junction of sample 3 S3(A) in multilayer welds. The complex multilayer microstructures can induce and produce unique hardness properties for battery manufacturing. It leads to high quality and durable welds. Eventually, it is experimentally demonstrated that robust 40 layer welded joints can be obtained by the UDRW process. Data availability: The datasets used and/or analyzed during the current study are available from the corresponding author upon reasonable request.http://www.sciencedirect.com/science/article/pii/S1110016824008068Ultrasonic double roller weldingCopper foils40 layersMechanical testingSEM and EDS analysisLithium-ion batteries |
| spellingShingle | Zeshan Abbas Lun Zhao Jianxiong Su Peng Zhang Jianxiong Deng Zeng Jiaqi Vivek Patel Hafiz Abdul Saboor Md Shafiqul Islam Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding Alexandria Engineering Journal Ultrasonic double roller welding Copper foils 40 layers Mechanical testing SEM and EDS analysis Lithium-ion batteries |
| title | Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding |
| title_full | Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding |
| title_fullStr | Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding |
| title_full_unstemmed | Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding |
| title_short | Investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding |
| title_sort | investigation of forming quality and failure behaviours of multilayered welded joints using ultrasonic double roller welding |
| topic | Ultrasonic double roller welding Copper foils 40 layers Mechanical testing SEM and EDS analysis Lithium-ion batteries |
| url | http://www.sciencedirect.com/science/article/pii/S1110016824008068 |
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