CN112462027A - Tracing method for metal plastic flow in ultrasonic welding process - Google Patents
Tracing method for metal plastic flow in ultrasonic welding process Download PDFInfo
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- CN112462027A CN112462027A CN202011125359.3A CN202011125359A CN112462027A CN 112462027 A CN112462027 A CN 112462027A CN 202011125359 A CN202011125359 A CN 202011125359A CN 112462027 A CN112462027 A CN 112462027A
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 86
- 239000002184 metal Substances 0.000 title claims abstract description 86
- 238000003466 welding Methods 0.000 title claims abstract description 77
- 238000000034 method Methods 0.000 title claims abstract description 56
- 239000004033 plastic Substances 0.000 title claims abstract description 42
- 230000008569 process Effects 0.000 title claims abstract description 36
- 239000011888 foil Substances 0.000 claims abstract description 24
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 23
- 239000011889 copper foil Substances 0.000 claims description 19
- 238000003475 lamination Methods 0.000 claims description 5
- 230000003287 optical effect Effects 0.000 claims description 4
- 238000005498 polishing Methods 0.000 claims description 4
- 238000005520 cutting process Methods 0.000 claims description 3
- 239000000700 radioactive tracer Substances 0.000 description 12
- 239000002245 particle Substances 0.000 description 8
- 239000000463 material Substances 0.000 description 7
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 6
- 238000009826 distribution Methods 0.000 description 6
- 239000000843 powder Substances 0.000 description 5
- 238000004506 ultrasonic cleaning Methods 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 229910000765 intermetallic Inorganic materials 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 229910001928 zirconium oxide Inorganic materials 0.000 description 2
- 101100136092 Drosophila melanogaster peng gene Proteins 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
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- 238000006467 substitution reaction Methods 0.000 description 1
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- 230000008961 swelling Effects 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/20—Metals
- G01N33/207—Welded or soldered joints; Solderability
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
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- G01N1/34—Purifying; Cleaning
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- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
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Abstract
The invention relates to a tracing method for metal plastic flow in an ultrasonic welding process. The tracing method is characterized in that metal foils with certain thicknesses are overlapped together, then the metal foils are placed between a lower sound pole and an upper sound pole of ultrasonic equipment for ultrasonic welding, and the plastic flow direction of metal in the ultrasonic welding process is displayed by observing the relative positions, deformation, bulging, fracture and other conditions of all layers of metal foils, so that the tracing purpose of the plastic flow of the metal is achieved. The invention can trace the metal plastic flow state of the whole welding joint in large range and three-dimensional space, and has the advantages of simple and rapid operation, low cost and the like.
Description
Technical Field
The invention relates to the field of ultrasonic welding, in particular to a metal plastic flow tracing method in an ultrasonic welding process. The tracing method is characterized in that metal foils with certain thicknesses are overlapped together, then the metal foils are placed between a lower sound pole and an upper sound pole of ultrasonic equipment for ultrasonic welding, and the plastic flow direction of metal in the ultrasonic welding process is displayed by observing the relative positions, deformation, bulging, fracture and other conditions of all layers of metal foils, so that the tracing purpose of the plastic flow of the metal is achieved.
Background
With the popularization of electric vehicles and the advancement of automotive technology, new requirements are placed on the connection of multilayer laminates, highly reflective and conductive materials in battery cells. Compared with the traditional fusion welding technology, the research and the industrial application of the ultrasonic welding technology are more and more extensive due to the elimination of metallurgical defects such as intermetallic compounds (IMC), brittle phases and pores in liquid phase reaction of a fusion zone, the research on the welding mechanism of the ultrasonic welding method has important significance for promoting and expanding the industrial application of the ultrasonic welding method, and the research on the plastic flow direction of metal in the ultrasonic welding process is a main technical method for clarifying the welding mechanism of the ultrasonic welding. The current commonly used tracing method for material flow during welding is particle embedding. The main principle of the method is that a small hole is drilled at a specific position of a workpiece, certain powder different from the chemical composition of the workpiece is embedded into the hole to serve as tracer particles, the tracer particles move along with the flow of welding metal in the welding process and are redistributed in a welding seam, and the final state distribution change of the tracer particles at the specific position is analyzed after welding, so that the flow rule of plastic metal is indirectly deduced (as shown in figure 1).
For example, Peng et al obtained the rule of influence of wire filling on the flow of the molten pool surface by a SiC particle tracing method, and analyzed the influence of different welding processes, wire filling modes and wire feeding angles on the fluctuation behavior of the molten pool surface and the weld formation (influence of laser wire filling welding on the dynamic behavior of the molten pool and the weld formation, Chinese laser, 11 th stage in 2017, pages 66-73).
For example, in the invention patent "method for tracking electromagnetic pulse welding metal jet by using tracer particles" (CN 110666331 a), blind holes are drilled on the surface to be welded of an aluminum plate, zirconia powder is added as tracer particles, zirconia follows the jet flow on the metal surface after collision, and the distribution of the metal jet flow is represented in the interface distribution range by using the zirconia powder. The zirconium oxide has high melting point, so that the interference of other factors in the movement process of the metal jet flow is avoided, and the distribution of the metal jet flow can be effectively expressed by virtue of the distribution of the zirconium oxide in the interface.
However, the conventional tracing method is added into the metal plate through powder, which has disadvantages of cumbersome process, narrow tracing area, interference of added powder particles with plastic flow of metal, and the like.
The invention superposes metal foils with certain thickness together, flattens the upper and lower surfaces, then places the metal foils between the lower sonotrode and the upper sonotrode of ultrasonic equipment for ultrasonic welding, and displays the plastic flow direction of metal in the ultrasonic welding process by observing the relative position, deformation, bulge, fracture and other conditions between the metal foils, thereby realizing the tracing of the plastic flow of the metal in the ultrasonic welding process.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a metal plastic flow tracing method in an ultrasonic welding process. And observing the relative position, deformation, bulging, fracture and other conditions of each layer of metal foil on the cross section of the metal foil welding joint by using an optical microscope so as to display the plastic flow direction of the metal in the ultrasonic welding process, thereby realizing the tracing of the plastic flow of the metal in the ultrasonic welding process. The ultrasonic welding joint is directly observed without adding a tracer material, so that the interference of metal plastic flow in the welding process caused by the addition of the tracer material is avoided; meanwhile, the welding joint is composed of a plurality of layers of metal foils, and the metal plastic flow state of the whole welding joint in a large range and a three-dimensional space can be traced; but also has the advantages of simple and rapid operation, low cost and the like.
The technical scheme of the invention is as follows:
(1) metal copper foils with certain thicknesses are overlapped together, and the upper surface and the lower surface are pressed to be flat;
(2) placing the metal foil lamination between a lower sound pole and an upper sound pole of ultrasonic equipment, and carrying out ultrasonic welding to obtain an ultrasonic welding joint;
(3) cutting and polishing the welding joint to obtain a bright cross section;
(4) and observing the relative position, deformation, swelling and fracture conditions among the metal copper foils on each layer on the cross section by using an optical microscope so as to display the plastic flow direction of the metal in the ultrasonic welding process, thereby realizing the tracing of the plastic flow of the metal in the ultrasonic welding process.
The thickness of the metal copper foil is 0.01-0.10 mm, and the number of superposed layers of the metal copper foil is 10-50.
The invention has the advantages that: (1) the ultrasonic welding joint is directly observed without adding additional tracer materials; (2) the interference of metal plastic flow in the welding process caused by the addition of a tracer material is avoided; (3) the welding joint is composed of a plurality of layers of metal foils, and can trace the metal plastic flow state of the whole welding joint in a large range and a three-dimensional space; (4) simple and quick operation and low cost.
Drawings
FIG. 1 is a graph of a distribution of refractory tungsten tracer elements;
FIG. 2 is a schematic view showing an ultrasonic welding apparatus and a metal copper foil being stacked;
FIG. 3a photograph of a cross-section of a 20-layer copper foil ultrasonic weld joint;
FIG. 3b is an enlarged view of a portion of the protrusion of FIG. 3a under a light mirror;
FIG. 3c is an enlarged view of a portion of the metal foil of FIG. 3a under a light mirror at a break;
FIG. 3d is an enlarged view of a portion of the recess of FIG. 3a under a light mirror;
FIG. 3e is a simplified schematic of FIG. 3 b;
FIG. 3f is a simplified schematic of FIG. 3 c;
FIG. 3g is a simplified schematic of FIG. 3 d;
FIG. 4a is a photograph of a cross-section of a 10-layer copper foil ultrasonic weld joint;
FIG. 4b is an enlarged view of a portion of the underside of the mirror recessed in FIG. 4 a;
FIG. 4c is an enlarged view of a portion of the protrusion of FIG. 4a under a light mirror;
FIG. 4d is an enlarged, partial, under-the-lens view of the break in FIG. 4 a;
FIG. 4e is a simplified schematic of FIG. 4 b;
FIG. 4f is a simplified schematic of FIG. 4 c;
FIG. 4g is a simplified schematic of FIG. 4 d;
FIG. 5a photograph of a cross-section of a 50-layer copper foil ultrasonic weld joint;
FIG. 5b is an enlarged view of a portion of the underside of the mirror recessed in FIG. 5 a;
FIG. 5c is an enlarged view of a portion of the protrusion of FIG. 5a under a light mirror;
FIG. 5d is an enlarged, partial, under-the-lens view of the break in FIG. 5 a;
FIG. 5e is a simplified schematic of FIG. 5 b;
FIG. 5f is a simplified schematic of FIG. 5 c;
fig. 5g is a simplified schematic of fig. 5 d.
Detailed Description
The above and other objects, features and advantages of the present invention will become more apparent from the following description of the embodiments of the present invention with reference to the accompanying drawings. The present invention is described below based on embodiments, and it will be understood by those of ordinary skill in the art that the drawings provided herein are for illustrative purposes and are not necessarily drawn to scale.
Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is, what is meant is "including, but not limited to".
Example 1
FIG. 2 is a schematic view showing the ultrasonic welding apparatus and the metal copper foil being stacked. And connecting an ultrasonic generator with an energy converter, connecting the energy converter with an upper sound pole through an energy concentrator, and placing metal copper foils which are overlapped together between the upper sound pole and a lower sound pole. The procedure for tracing the plastic flow direction of metal in the ultrasonic welding process is as follows.
(1) And (3) superposing 20 layers of copper foils with the thickness of 0.01mm, and flattening the upper surface and the lower surface.
(2) And placing the metal foil laminate between a lower sound pole and an upper sound pole of ultrasonic equipment for ultrasonic welding, and obtaining the ultrasonic welding joint under the process parameter conditions of 1.5atm of welding pressure, 0.15s of welding time and 50% of amplitude.
(3) Cutting off the welding joint, and cold-embedding by using epoxy resin and an epoxy resin curing agent; then, grinding with 400#, 800#, 1200#, 2000#, 3000# sandpaper respectively; polishing the polished sample by using a polishing machine and adding a diamond suspension with the granularity of 0.25 mu m; and (3) putting the polished sample into a container filled with absolute ethyl alcohol, and then putting the container into an ultrasonic cleaning machine for ultrasonic cleaning, wherein the ultrasonic cleaning time is set to be 10 min. And taking out the cleaned sample, and then drying the sample to finally obtain the cross section of the bright ultrasonic welding joint.
(4) The relative position, deformation, bulging, fracture and the like of each layer of metal foil on the cross section are observed by an optical microscope, so that the plastic flow direction of the metal in the ultrasonic welding process is displayed, and the tracing of the plastic flow of the metal in the ultrasonic welding process is realized (as shown in figure 3 a). The black thick arrows in fig. 3e, f, g indicate the metal plastic flow direction, the protrusion of the laminated copper foil can be clearly seen from fig. 3b to form a peak, the main information is refined and the secondary information is simplified to obtain fig. 3e, and the metal plastic flow direction at the position, namely the metal on both sides of the peak moves and gathers to the peak top position to form a convex peak can be clearly obtained by comparing with the original state of the foil lamination in fig. 2. This is due to the flow of metal material from the area under the upper sonotrode projection to fill the space at the upper sonotrode depression during the ultrasonic welding process. Fig. 3f shows that the fracture occurs at the junction of the projection and the recess of the upper sonotrode, along with the progress of the welding process, the metal filling the space at the recess of the upper sonotrode gradually increases to a certain value and does not increase, the metal near the recess of the upper sonotrode does not gather at the recess any more, but is continuously extruded to move towards the opposite direction, the metal at the recess of the upper sonotrode continuously moves to be matched with and fills the recess of the upper sonotrode, and therefore the copper foil is stretched to cause the fracture. For the same reason, fig. 3g also illustrates the plastic flow direction of the metal. At the initial stage of the welding process, the laminated copper foil is gathered towards the concave part of the upper sonotrode, the metal containing amount of the concave part reaches the maximum value along with the progress of the welding process, and the copper foil is not gathered towards the concave part, but is continuously compressed, and further deforms and overlaps.
Example 2
The number of the copper foil layers in example 1 was changed to 10, and the ultrasonic welded joint was obtained under the process parameters of 1.5atm welding pressure, 0.10s welding time and 30% amplitude in the same procedure, thereby tracing the plastic flow of the metal during the ultrasonic welding process (as shown in fig. 4 a). The black thick arrow directions in fig. 4e, f and g are shown as the metal plastic flow directions, it can be clearly seen from fig. 4b that the laminated copper foil forms an indent, the main information is refined and the secondary information is simplified to obtain fig. 4e, and by comparing with the original state of the foil lamination in fig. 2, the metal plastic flow directions at the position can be clearly obtained, that is, the metals at the two sides of the indent move and gather to the valley position, and then the valley of the indent is formed. FIG. 4f shows the metal on both sides of the peak moving and gathering to the top of the peak to form a convex peak. Fig. 4f shows the stretching of the copper foil resulting in fracture. Similarly, FIG. 4g also illustrates the direction of plastic flow of the metal.
Example 3
The number of the copper foil layers in example 1 was changed to 50 layers, and the ultrasonic welded joint was obtained under the process parameters of welding pressure of 2.0atm, welding time of 0.15s, and amplitude of 60% in the same manner as the other steps, thereby tracing the plastic flow of the metal during the ultrasonic welding process (as shown in fig. 5 a). The black thick arrows in fig. 5e, f, g indicate the metal plastic flow direction, it can be clearly seen from fig. 5b that the laminated copper foil forms an indent, the main information is extracted and the secondary information is simplified to obtain fig. 5e, and by comparing with the original state of the foil lamination in fig. 2, the metal plastic flow direction at the position can be clearly obtained, that is, the metal on both sides of the indent moves and gathers to the valley position, and then the valley of the indent is formed. Fig. 5g shows the stretching of the copper foil resulting in fracture, and fig. 5g shows the direction of plastic flow of the metal. FIG. 5f shows the metal on both sides of the peak moving and gathering to the top of the peak to form a convex peak.
The ultrasonic welding joint is directly observed without adding a tracer material, so that the interference of metal plastic flow in the welding process caused by the addition of the tracer material is avoided; meanwhile, the welding joint is composed of a plurality of layers of metal foils, and the metal plastic flow state of the whole welding joint in a large range and a three-dimensional space can be traced; but also has the advantages of simple and rapid operation, low cost and the like.
It will be readily appreciated by those skilled in the art that the above-described preferred embodiments are freely combined, superimposed, and not subject to conflict.
The above description is only a preferred embodiment of the present invention, but the implementation manner of the present invention is not limited by the above embodiment, and any other changes, modifications, substitutions, combinations, simplifications which do not depart from the spirit and principle of the present invention should be regarded as equivalent replacements within the protection scope of the present invention.
Claims (3)
1. A tracing method for metal plastic flow in an ultrasonic welding process is characterized in that:
(1) stacking metal foils with certain thicknesses together, and flattening the upper surface and the lower surface;
(2) placing the metal foil lamination between a lower sound pole and an upper sound pole of ultrasonic equipment, and carrying out ultrasonic welding to obtain an ultrasonic welding joint;
(3) cutting and polishing the welding joint to obtain a bright cross section;
(4) and observing the relative position, deformation, bulging and fracture conditions among the metal foils on each layer on the cross section by using an optical microscope so as to display the plastic flow direction of the metal in the ultrasonic welding process, thereby realizing the tracing of the plastic flow of the metal in the ultrasonic welding process.
2. The method of claim 1, wherein the metallic copper foil has a thickness of 0.01 to 0.10 mm.
3. The method according to claim 1, wherein the number of stacked layers of the metallic copper foil is 10 to 50.
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| CN202011125359.3A CN112462027A (en) | 2020-10-20 | 2020-10-20 | Tracing method for metal plastic flow in ultrasonic welding process |
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| CN202011125359.3A CN112462027A (en) | 2020-10-20 | 2020-10-20 | Tracing method for metal plastic flow in ultrasonic welding process |
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Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5651494A (en) * | 1995-03-17 | 1997-07-29 | Nippondenso Co., Ltd. | Method of ultrasonic welding of different metals |
| JP2011115814A (en) * | 2009-12-02 | 2011-06-16 | Hitachi Vehicle Energy Ltd | Ultrasonic welding method of metal thin plate |
-
2020
- 2020-10-20 CN CN202011125359.3A patent/CN112462027A/en active Pending
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5651494A (en) * | 1995-03-17 | 1997-07-29 | Nippondenso Co., Ltd. | Method of ultrasonic welding of different metals |
| JP2011115814A (en) * | 2009-12-02 | 2011-06-16 | Hitachi Vehicle Energy Ltd | Ultrasonic welding method of metal thin plate |
Non-Patent Citations (3)
| Title |
|---|
| 桑健等: "T2铜箔热辅助超声波增材制造工艺", 《材料导报》 * |
| 蒋召平等: "铝/铜异质金属超声波焊接工艺研究", 《焊接技术》 * |
| 赵玉津等: "铝铜超声波焊接接头性能的正交试验分析", 《天津大学学报(自然科学与工程技术版)》 * |
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Application publication date: 20210309 |