Abstract
A multiscale simulation approach was developed and employed to optimize the sheet surface conditions for higher interfacial temperature and joint strength in ultrasonic welding of magnesium alloy AZ31 and dual-phase steel DP590. First, a mesoscale model was used to study the relationship between friction coefficient and surface roughness, which can be modified by various engineering methods. Then a macroscopic process model was employed to study the effects of surface roughness on heat generation, indicating that a temperature increase can be achieved with rougher surfaces on two sides of both DP590 and AZ31 sheets. Samples prepared by sanding and filing, as well as grinding, were first characterized for surface roughness and then welded under ultrasonic vibration. An infrared camera was used to measure temperatures in situ for model validation. Lap shear test results for the welded joint showed that the joint strength can be improved by 10~25% using filing and round grinding methods as a result of the enhanced heat generation and mechanical interlocking on the interface.
| Original language | English |
|---|---|
| Pages (from-to) | 3095-3109 |
| Number of pages | 15 |
| Journal | International Journal of Advanced Manufacturing Technology |
| Volume | 111 |
| Issue number | 11-12 |
| DOIs | |
| State | Published - Dec 2020 |
Funding
This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, and worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). The help of Kyle Doug and Alan Frederick of ORNL’s Materials Joining Group in preparing the samples is acknowledged with appreciation. The authors are grateful to Dr. Jun Qu for fruitful discussions on the friction modeling. We also express thanks to POSCO and US Steel for providing materials in the study. This research was sponsored by the US Department of Energy, Office of Vehicle Technologies, under a prime contract with Oak Ridge National Laboratory (ORNL). ORNL is managed by UT-Battelle LLC for the US Department of Energy under Contract DE-AC05-00OR22725. Acknowledgments
Keywords
- Friction
- Heat transfer
- Numerical model
- Surface engineering
- Ultrasonic welding