Mechanical Behavior and Microstructure of Ultrasonic-Spot-Welded Al/Cu Dissimilar Joints with Zn Interlayer

Chunjie Li; Sansan Ao; Anqi Wang; Qi Wei; Manpeng Wu; Zhen Luo

doi:10.1007/s12209-019-00221-y

Transactions of Tianjin University ›› 2020, Vol. 26 ›› Issue (4) : 305 -313. DOI: 10.1007/s12209-019-00221-y

Research Article

Mechanical Behavior and Microstructure of Ultrasonic-Spot-Welded Al/Cu Dissimilar Joints with Zn Interlayer

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¹ School of Materials Science and Engineering, Tianjin University, 300350, Tianjin, China

^b ao33@tju.edu.cn

Chunjie Li received her BS degree in materials processing (2018) from Nanchang University, China. At present, she is a masters candidate of the School of Materials Science and Engineering, Tianjin University, China. Her current research interest is focused on ultrasonic spot welding (USW).

Sansan Ao received his BS degree in materials processing (2007) from Hebei University of Science and Technology and his MS degree (2009) and PhD degree in materials processing (2012) from Tianjin University, China. During 2014–2015, he was a post-doctoral research fellow in University of South Carolina, USA. At present, he is a full associate professor at the School of Materials Science and Engineering, Tianjin University, China. He has published more than 30 research journal publications. His current research interests are focused on ultrasonic spot welding (USW) and wire and arc additive manufacturing (WAAM).

AnqI Wang is a senior undergraduate and will receive her bachelors degree in 2020. As a senior, she is participating in the project research on ultrasonic spot welding.

Qi Wei is a senior undergraduate and will receive his bachelors degree in 2020. As a senior, he is participating in the project research on ultrasonic spot welding.

Manpeng Wu received his BS degree in metal materials engineering (2006) and MS degree (2017) in materials engineering processing both from Jiangsu University of Science and Technology. At present, he is a PhD candidate at the School of Materials Science and Engineering, Tianjin University, China.

Zhen Luo received his BS degree in power engineering (1988) from University of Shanghai for Science and Technology, his MS degree (1995) in mechatronics engineering from Harbin Institute of Technology, and his PhD degree in materials processing (2003) from Tianjin University, China. At present, he is a full professor at the School of Materials Science and Engineering, Tianjin University, China. He has published more than 200 research journal publications. His current research interests are focused on ultrasonic spot welding (USW), wire and arc additive manufacturing (WAAM), and resistance spot welding.

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Abstract

The effect of Zn interlayer on the microstructural evolution and mechanical behavior of dissimilar ultrasonic-spot-welded Al/Cu joints was investigated. The tensile lap shear strength in relation to welding energy was analyzed. The experimental results show that two intermetallic compounds, Cu₅Zn₈ and Al₂Cu, were generated at the interface of the ultrasonic-spot-welded Al/Cu joint with a Zn interlayer. The primary joining mechanisms of the joint included the intermetallic compound bonding and metallic bonding caused by solid shear plastic deformation. Meanwhile, with increasing welding energy, the plastic deformation of the material became more substantial. With increasing welding energy, the tensile lap shear strength of the joints first increased and then decreased for the ultrasonic-spot-welded Al/Cu joints with and without Zn interlayers. Under the energy input of 700 J, the bearing load capacity of the ultrasonic-spot-welded Al/Cu joints with a Zn interlayer improved significantly due to the observed intermetallic compound (Cu₅Zn₈).

Keywords

Zn interlayer / Ultrasonic spot welding / Dissimilar joints / Plastic deformation / Welding energy

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Chunjie Li, Sansan Ao, Anqi Wang, Qi Wei, Manpeng Wu, Zhen Luo. Mechanical Behavior and Microstructure of Ultrasonic-Spot-Welded Al/Cu Dissimilar Joints with Zn Interlayer. Transactions of Tianjin University, 2020, 26(4): 305-313 DOI:10.1007/s12209-019-00221-y

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