journal article·2020-12

Ultrasonic spot welding of a clad 7075 aluminum alloy: Strength and fatigue life

S.M.A.K. Mohammed, Y.D. Jaya, A. Albedah, X.Q. Jiang, D.Y. Li, D.L. Chen

Publisher page

Abstract

Abstract The purpose of this study was to examine weldability of an AA7072-cladded high-strength AA7075-T6 via ultrasonic spot welding, focusing on the influence of welding energy on mechanical properties and failure mechanisms. Defect-free sound joints were achieved with robust bonding and grain refinement via dynamic recrystallization at the weld interface, leading to superior static and fatigue properties. The nominal tensile lap shear strength increased with increasing welding energy, and exceeded AWS D17.2 standards at higher energy levels. Interfacial failure at higher cyclic loads with distinctive elongated shear dimples and fatigue striations and transverse through-thickness failure at lower cyclic loads were observed.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Advanced Welding Techniques Analysis · Aluminum Alloys Composites Properties · Aluminum Alloy Microstructure Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (76)

Show source-provided references
1. Toward lighter, stiffer materials10.1126/science.1243996 ↗
2. Corrosion avoidance in lightweight materials for automotive applications10.1038/s41529-018-0045-2 ↗
3. Light alloys
4. ASM Handbook. Properties and Selection: Nonferrous alloys and special-purpose materials. 2nd ed.; 2018. Doi: 10.31399/asm.hb.v02.9781627081627.10.31399/asm.hb.v02.9781627081627 ↗
5. Friction stir welding of co-cast aluminium clad sheet10.1179/1362171813Y.0000000155 ↗
6. Dif R, Bes B, Lassince P, Ribes H. Clad aluminum alloy sheet for aircraft structural parts. US 6,528,183; 2003.
7. Welding versus casting and riveted structures10.1049/jipe.1948.0001 ↗
8. Scientific, technological and economic issues in metal printing and their solutions10.1038/s41563-019-0408-2 ↗
9. Joining aluminum sheet in the automotive industry—A 30 year history
10. Nanoparticle-enabled phase control for arc welding of unweldable aluminum alloy 707510.1038/s41467-018-07989-y ↗
11. Effect of various welding parameters on corrosion behavior of friction-stir-welded AA 7075–T651 alloys10.1007/s13632-018-0440-7 ↗
12. Martin JH, Yahata B. Aluminum alloy components from additive manufacturing. US20190161835A1; 2019.
13. Improving aluminum resistance spot welding in automotive structures
14. Sigler DR, Karagoulis MJ. Weld schedule for resistance spot welding of aluminum alloy workpieces. US20130048613A1; 2013.
15. Effect of external magnetic field on resistance spot welding of aluminum alloy AA6061-T610.1016/j.jmapro.2020.01.005 ↗
16. Welding aspects of aluminum–lithium alloys10.1016/B978-0-12-401698-9.00009-4 ↗
17. Vural M. Welding processes and technologies. Compr Mater Process, vol. 6, Elsevier; 2014. p. 3–48. doi: 10.1016/B978-0-08-096532-1.00603-8.10.1016/B978-0-08-096532-1.00603-8 ↗
18. Friction stir welding and processing10.1016/j.mser.2005.07.001 ↗
19. Microstructure and failure mechanisms of refill friction stir spot welded 7075–T6 aluminum alloy joints10.1016/j.matdes.2012.08.026 ↗
20. Advances in friction stir spot welding
21. Microstructure and fatigue properties of linear friction welded TC4 titanium alloy joints10.1080/13621718.2016.1212971 ↗
22. Fracture characteristics and analysis in dissimilar Cu-Al alloy joints formed via electromagnetic pulse welding10.3390/ma12203368 ↗
23. The mechanics of wave formation in explosive welding
24. Ultrasonic spot welding of Al sheets by enhancing the temperature of weld interface10.1016/j.matlet.2017.05.009 ↗
25. Patel VK, Bhole SD, Chen DL. Ultrasonic spot welding of lightweight alloys. In: Yu SW, Feng XQ, editors. Proc 13th Int Conf Fract, Beijing, China: The Chinese Society of Theoretical and Applied Mechanics (CSTAM); 2013, p. Paper No. S01-011.
26. Ultrasonic spot welding of magnesium-to-aluminum alloys with a copper interlayer: Microstructural evolution and tensile properties10.1016/j.jmapro.2018.11.008 ↗
27. Guo J. Solid state welding processes in manufacturing welding process manufacturing. Handb. Manuf. Eng. Technol., London: Springer London; 2015, p. 569–92. Doi: 10.1007/978-1-4471-4670-4_55.10.1007/978-1-4471-4670-4_55 ↗
28. Mathers G. The welding of aluminium and its alloys. Woodhead Publishing Limited; 2002. Doi: 10.1533/9781855737631.10.1201/9781439823224 ↗
29. Sindo Kou. Welding Metallurgy. John Wiley & Sons; 2010. Doi: 10.1201/9781439823224.ch2.10.1201/9781439823224.ch2 ↗
30. Matheny MP, Frech T, Short MA, Gould J, Workman D, Lindamood L. Hybrid ultrasonic and resistance spot welding system. US20200108468A1; 2020.
31. Junction growth in ultrasonic spot welding and ultrasonic additive manufacturing10.1016/j.actamat.2018.07.058 ↗
32. Patel VK, Bhole SD, Chen DL, Ni DR, Xiao BL, Ma ZY. Ultrasonic spot welding of dissimilar 2024Al alloy and SiCp/2009Al composite. Proc Inst Mech Eng Part L J Mater Des Appl; 2018:146442071880913. Doi: 10.1177/1464420718809133.10.1177/1464420718809133 ↗
33. Ultrasonic spot welding of 5182 aluminum alloy: Evolution of microstructure and mechanical properties10.1016/j.msea.2019.04.059 ↗
34. Similar and dissimilar ultrasonic spot welding of 5754 aluminum alloy for automotive applications10.4028/www.scientific.net/MSF.877.561 ↗
35. Microstructure and mechanical properties of an ultrasonic spot welded aluminum alloy: The effect of welding energy10.3390/ma10050449 ↗
36. Ultrasonic metal welding process: Robustness in aluminum automotive body construction applications
37. Novel approaches to friction spot welding thin aluminium automotive sheet10.4028/www.scientific.net/MSF.638-642.1237 ↗
38. Ultrasonic spot welded 6111–T4 aluminum alloy to galvanized high-strength low-alloy steel: Microstructure and mechanical properties10.1016/j.matdes.2016.10.025 ↗
39. Ultrasonic spot welding of aluminum alloys: A review10.1016/j.jmapro.2018.09.009 ↗
40. Ultrasonic welding of magnesium alloys: a review
41. Ultrasonic spot welding of aluminum to copper: a review10.1007/s00170-020-04997-5 ↗
42. A review on ultrasonic spot welding of copper alloys10.1080/02670836.2019.1705590 ↗
43. Ultrasonic spot welding of dissimilar Al 6022 and Al 7075 alloys10.1016/j.jmatprotec.2019.116460 ↗
44. Microstructure and mechanical properties of ultrasonic spot welded copper-to-magnesium alloy joints10.1016/j.matdes.2015.06.104 ↗
45. In-situ measurement of relative motion during ultrasonic spot welding of aluminum alloy using photonic Doppler velocimetry10.1016/j.jmatprotec.2016.01.006 ↗
46. Macwan A, Chen DL. Similar and dissimilar ultrasonic spot welding of a rare-earth containing ZEK100 magnesium alloy. Magnes. Technol. 2016, Cham: Springer International Publishing; 2016, p. 109–13. Doi: 10.1007/978-3-319-48114-2_23.10.1002/9781119274803.ch23 ↗
47. Influence of ultrasonic spot welding on microstructure in a magnesium alloy10.1016/j.scriptamat.2011.08.009 ↗
48. Microstructure and fatigue properties of ultrasonic spot welded joints of aluminum 5754 alloy10.1007/s11837-015-1796-7 ↗
49. Ultrasonic spot welding of a rare-earth containing ZEK100 magnesium alloy: Effect of welding energy10.1007/s11661-016-3355-4 ↗
50. Singh · 2015
51. Souza SH de, Padilha AF, Kliauga AM. Softening behavior during annealing of overaged and cold-rolled aluminum alloy 7075. Mater Res 2019;22. Doi: 10.1590/1980-5373-mr-2018-0666.10.1590/1980-5373-mr-2018-0666 ↗
52. Recrystallization in commercially pure aluminum10.1007/BF02645114 ↗
53. Effects of solute Fe, Zn and Mg on recrystallization in aluminum10.2320/matertrans.MBW201515 ↗
54. Effect of welding parameters on nugget zone microstructure and properties in high strength aluminium alloy friction stir welds10.1179/136217103225005480 ↗
55. Local melting and cracking in Al 7075–T6 and Al 2024–T3 friction stir spot welds10.1179/174329307X213873 ↗
56. The influence of higher surface hardness on fretting fatigue life of hard anodized aerospace AL7075-T6 alloy10.1016/j.msea.2012.09.082 ↗
57. Microstructure and cyclic deformation behavior of a friction-stir-welded 7075 Al alloy10.1007/s11661-009-0152-3 ↗
58. Evolution of microstructure and mechanical properties in a single-stage aged 7075 aluminum alloy pulse variable polarity plasma arc welded joint10.3390/met9040428 ↗
59. Improving weld strength of magnesium to aluminium dissimilar joints via tin interlayer during ultrasonic spot welding10.1179/1362171812Y.0000000013 ↗
60. Effect of re-aging on strength, corrosion and dry sliding wear behavior of 7075 aluminum alloy
61. American Welding Society. AWS D17.3 - Specification for friction stir welding of aluminum alloys for aerospace applications. 2nd ed. American Welding Society; 2016.10.1201/9781315116815-2 ↗
62. American Welding Society. AWS D17.2 - Specification for resistance welding for aerospace applications. 2nd ed. American Welding Society; 2013.
63. Microstructural evolution and mechanical properties of refill friction stir spot welded Alclad 2A12-T4 aluminum alloy10.1016/j.jmrt.2019.07.021 ↗
64. Effect of Alclad layer on material flow and defect formation in friction-stir-welded 2024 aluminum alloy10.1007/s11661-010-0545-3 ↗
65. Ultrasonic spot welding of aluminum to high-strength low-alloy steel: Microstructure, tensile and fatigue properties10.1007/s11661-013-2123-y ↗
66. Effect of welding energy on microstructure and strength of ultrasonic spot welded dissimilar joints of aluminum to steel sheets10.1016/j.msea.2016.05.040 ↗
67. Ultrasonic spot welding of aluminium to steel for automotive applications—microstructure and optimisation10.1179/026708310X520484 ↗
68. Effect of ultrasonic welding parameters on microstructure and mechanical properties of dissimilar joints10.1016/j.matdes.2013.09.074 ↗
69. Stress intensities at spot welds10.1023/A:1007461430066 ↗
70. Simplified formulae for stress intensity factors of spot welds10.1016/0013-7944(91)90142-N ↗
71. Understanding the factors controlling the interfacial failure strength of advanced high-strength steel resistance spot welds: hardness vs. fracture toughness10.1080/13621718.2017.1421303 ↗
72. The effect of tensile strength on the fatigue life of spot-welded sheet steels
73. Microstructure and fatigue performance of single and multiple linear fiber laser welded DP980 dual-phase steel10.1016/j.msea.2012.05.091 ↗
74. Tensile and fatigue properties of fiber laser welded high strength low alloy and DP980 dual-phase steel joints10.1016/j.matdes.2012.07.017 ↗
75. Microstructure and mechanical properties of ultrasonic spot welded Mg/Al alloy dissimilar joints10.3390/met8040229 ↗
76. Microstructure and fracture characteristics of spot-welded DP600 steel10.1016/j.msea.2007.08.010 ↗