Mechanisms of joint formation in ultrasonic spot welding aluminium automotive sheet

D. Bakavos, Y. C. Chen, P. B. Prangnell

    Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review


    High power ultrasonic spot welding (HP-USW) is an extremely efficient new method for welding Al alloys, using ∼2% of the energy of resistance spot welding (RSW). The overall objective of mis work was to improve me current poor understanding of me mechanisms of weld formation, when HP-USW is applied to aluminium automotive sheet. To this end, results are reported where we have studied me material flow, combined with, X-ray tomography, and electron microscopy, to characterise me weld defects, stages of weld formation, and microstructure evolution, as a function of welding energy, for a standard automotive material AA6111-T4 (0.92 mm thick sheet). The origin of me complex flow features, seen in HP-USW, are discussed and were found to occur on three characteristic length scales.
    Original languageEnglish
    Title of host publicationTMS Annual Meeting|TMS Annu Meet
    Place of PublicationWarrendale, PA
    PublisherMinerals, Metals & Materials Society
    Number of pages7
    ISBN (Print)9781118029459
    Publication statusPublished - 2011
    EventTMS 2011 - 140th Annual Meeting and Exhibition - San Diego, CA
    Duration: 1 Jul 2011 → …


    ConferenceTMS 2011 - 140th Annual Meeting and Exhibition
    CitySan Diego, CA
    Period1/07/11 → …


    • AA6111
    • Aluminium
    • Microbonding
    • Tomography, flow features, lap shear strength
    • Ultrasonic welding


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