| MATERIALS AND SUSTAINABLE DEVELOPMENT: GREEN MANUFACTURING AND PROCESSING OF MATERIALS |
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| Optimization Analysis of Ultrasonic Welding of Copper/Aluminum Electrode Lug Using Response Surface Method |
| ZHANG Yifu1,2, ZHANG Hua1, KUANG Jing 1,2, ZHU Zhengqiang1, PAN Jiluan1
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1 Key Laboratory for Robot & Welding Automation of Jiangxi Province, School of Mechanical & Electrical Engineering, Nanchang University, Nanchang 330031
2 School of Mechanics & Materials Engineering, Jiujiang University, Jiujiang 332005 |
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Abstract The ultrasonic welding test of lithium battery copper/aluminum electrode lug dissimilar metal was designed by response surface method. A multivariate nonlinear regression mathematical model was established by using the stepwise regression method to screen out the significant factors affecting the responses. The SEM, EDS, XRD, 3D depth-of-field microscopic analysis and micro-hardness tester were used to study the variation of microstructure morphology, phase structure, depth of field and hardness of copper/aluminum welded joints under optimal parameters, and to understand the mechanism of connection and intermetallic compounds (IMCs) generation. The results show that the influence of various process parameters on the tensile load has a very complex interaction, and the interface achieves no defect connection under optimal parameters. High strain rates accelerate the precipitation of Cu9Al4, CuAl and CuAl2 IMCs phase at the interface, and its thickness is about 8 μm. The plastic deformation propagates throughout the thickness of the foil, and the severe plastic deformation promotes the proliferation of dislocations. A transition layer consisting of nanocrystalline and amorphous phases is formed. The strength of the workpiece connection depends on the combined effect of mechanical interlocking, transition layers and element interdiffusion.
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Published: 21 May 2019
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| Fund:This work was financially supported by the National Natural Science Foundation of China (U1731118), the Key Laboratory of Lightweight and High Strength Structural Materials of Jiangxi Province (20171BCD40003). |
| About author:: Yifu Zhang is a 2016 Ph.D. student at Nanchang University and a lecturer at Jiujiang University, focusing on the research of the regulation of multiphase IMCs in dissimilar metal welding. More than 20 articles have been published in important journals at domestic and foreign.Hua Zhang is a professor and Ph.D. supervision at School of Mechanical & Electrical Engineering, Nanchang University. He graduated from Tsinghua University in 1997 with a Ph.D. in welding, focusing on the research of welding automation sensing, information processing, intelligent control, fusion welding rapid prototyping and fiber optic smart metal structures, etc. More than 100 articles have been published in important journals at domestic and foreign. |
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2019, Vol. 33 
