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Surface engineering to enhance heat generation and joint strength in dissimilar materials AZ31 and DP590 ultrasonic welding

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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.

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Acknowledgments

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.

Funding

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.

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Authors and Affiliations

  1. Materials Science and Technology Division, Oak Ridge National Laboratory, 1 Bethel Valley Road, Oak Ridge, TN, 37831, USA

    Hui Huang, Jian Chen, Yong Chae Lim & Zhili Feng

  2. Energy and Transportation Science Division, Oak Ridge National Laboratory, 1 Bethel Valley Road, Oak Ridge, TN, 37831, USA

    Jiahao Cheng, Xiaohua Hu & Xin Sun

Authors
  1. Hui Huang
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  2. Jian Chen
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  3. Jiahao Cheng
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  4. Yong Chae Lim
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  5. Xiaohua Hu
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  6. Zhili Feng
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  7. Xin Sun
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Contributions

Hui Huang: conceptualization, writing—original draft preparation. Jian Chen: investigation, resources. Jiahao Cheng: software, review and editing. Yong Chae Lim: investigation, validation. Xiaohua Hu: investigation, reviewing and editing. Zhili Feng: reviewing and editing, supervision. Xin Sun: methodology, reviewing and editing, project administration.

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Correspondence to Hui Huang.

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Huang, H., Chen, J., Cheng, J. et al. Surface engineering to enhance heat generation and joint strength in dissimilar materials AZ31 and DP590 ultrasonic welding. Int J Adv Manuf Technol 111, 3095–3109 (2020). https://doi.org/10.1007/s00170-020-06341-3

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  • DOI: https://doi.org/10.1007/s00170-020-06341-3

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