CN117697114A - Al/Cu ultrasonic welding method with Zn foil as intermediate reaction layer - Google Patents

Al/Cu ultrasonic welding method with Zn foil as intermediate reaction layer Download PDF

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CN117697114A
CN117697114A CN202410039356.XA CN202410039356A CN117697114A CN 117697114 A CN117697114 A CN 117697114A CN 202410039356 A CN202410039356 A CN 202410039356A CN 117697114 A CN117697114 A CN 117697114A
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welding
foil
ultrasonic welding
reaction layer
intermediate reaction
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马国红
肖淋鸣
张丹
周永强
聂龙华
陈文忠
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Nanchang University
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Nanchang University
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Abstract

The invention provides an Al/Cu ultrasonic welding method taking Zn foil as an intermediate reaction layer, belonging to the technical field of dissimilar metal welding. The invention adds Zn foil as the welding joint of the middle layer, and adjusts and controls the type and the formation of the connecting interface compound by adopting the Zn foil as the transition layer in the high-power ultrasonic welding process, thereby preventing continuous brittle intermetallic compound (Al 2 Cu) and forms a large number of solid solutions and eutectic structures which effectively improve the tensile properties of the joint; and meanwhile, the peak temperature of the interface is higher than that of an interface without adding the middle layer, which is more beneficial to the welding process.

Description

Al/Cu ultrasonic welding method with Zn foil as intermediate reaction layer
Technical Field
The invention belongs to the technical field of dissimilar metal welding, and particularly relates to an Al/Cu ultrasonic welding method taking Zn foil as an intermediate reaction layer.
Background
As global energy and environmental issues become increasingly prominent, the automotive industry is actively transitioning to energy-efficient and environmentally friendly hybrid and new energy automobiles. The lithium ion battery is used as a main power source of the new energy automobile and is an important trend of the development of new energy products. However, copper is a heat and electricity conductive metal commonly used in the power and electronics industries, and is less stored and expensive. Accordingly, the development of materials that replace copper is needed to manufacture lithium ion batteries with high energy density, high efficiency, and long life.
In this field, aluminum and aluminum alloys have received much attention because of their low cost, light density, good heat and electrical conductivity, and high reserves. The aluminum/copper dissimilar material not only can meet the performance requirement of the lithium ion battery, but also accords with the development trend of light weight of products. Aluminum alloy is widely used as a material of a tab, a pole piece and a positive and negative current collector in a lithium ion battery, and meanwhile, an aluminum/copper sheet and a multi-layer sheet are inevitably required to be welded in the manufacturing process of a substrate and a connecting wire of an integrated chip. The performance and quality of aluminum/copper dissimilar welding have important influence on the overall performance, service life and other aspects of electronic devices, so that the realization of good and reliable aluminum/copper dissimilar welding is very important for the assembly of lithium ion batteries and capacitors.
Due to the large difference in the thermo-physical properties of aluminum and copper materials, it is quite difficult to achieve a good connection between them. Conventional fusion welding can cause defects such as air holes, impurities, intermetallic compounds and the like in aluminum and copper joints. The solid phase welding method can reduce the generation of intermetallic compounds, and is particularly suitable for welding aluminum and copper dissimilar materials. However, friction stir welding, friction welding, explosion welding and other methods are complicated to operate and are not suitable for welding aluminum and copper thin plates and multi-layer plates in electronic devices. The ultrasonic welding technology is an energy-saving and environment-friendly solid-phase welding method, is simple to operate, has short welding time, and is suitable for welding high-electric-conductivity and high-heat-conductivity materials. Because the welding temperature is low, the ultrasonic welding technology can well inhibit the generation of intermetallic compounds, and meets the requirements of aluminum and copper dissimilar welding joints. In addition, the ultrasonic welding technology has low requirements on the shape and the size of the welded material, and is particularly suitable for the connection of the tab and the pole piece of the lithium ion battery, the welding of aluminum and copper thin plates and the tube plate.
Document Effect of welding energy on interface zone of Al-Cu ultrasonic welded joint, sci.technology.gold.18 (2013) 354-360 welding experiments on aluminum/copper dissimilar joints were performed using ultrasonic welding under different welding parameters. The effect of welding energy on the strength, failure behavior and microstructure of an aluminum/copper ultrasonic welded joint was experimentally studied. The results show that the joint strength initially increases with increasing welding energy, reaches a maximum at 1000J, and then drops significantly. This is because at lower energies, a swirl-like structure occurs at the weld interface, resulting in a mechanical lock between the materials. However, at too high energy, cavity defects and brittle intermetallic compounds (Al 4 Cu 9 ) The formation of brittle intermetallic compounds is the most dominant factor leading to a decrease in joint strength. The presence of intermetallic compounds can affect the joint strength and also increase the resistance of aluminum/copper dissimilar metal joints, resulting in increased heat and power loss of the electrical equipment, and thus, the service life of the electrical equipment. Therefore, there is a need for an ultrasonic welding method for aluminum/copper dissimilar metals that can avoid the formation of intermetallic compounds to improve the strength of the aluminum/copper dissimilar metal welded article.
Disclosure of Invention
The invention aims to provide an Al/Cu ultrasonic welding method taking Zn foil as an intermediate reaction layer, which is characterized in that the type and the formation of a connecting interface compound are regulated and controlled by adopting Zn foil as a transition layer in the high-power ultrasonic welding process, so that the generation of an aluminum-copper brittle intermetallic compound is avoided, and the joint performance is further improved.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
an Al/Cu ultrasonic welding method taking Zn foil as an intermediate reaction layer comprises the following steps:
step one: performing surface treatment on an aluminum alloy plate, a copper plate and a Zn foil for standby;
step two: overlapping the treated aluminum alloy plate and the treated copper plate in a lap joint mode of 'copper on aluminum down', and placing Zn foil at the interface between the aluminum alloy plate and the copper plate to be welded for fixation;
step three: and (3) performing ultrasonic welding on the piece to be welded obtained in the step two, and cooling to obtain the product.
Preferably, in the step one, the aluminum alloy is 7075-T6 aluminum alloy, and the red copper is T2 red copper.
Preferably, the first surface treatment is to polish the surface by adopting metallographic sand paper, and finally, the surface treatment is to be immersed in absolute ethyl alcohol for ultrasonic cleaning.
Preferably, the second step further comprises processing a temperature measuring hole on the surface of the copper plate, wherein the depth of the temperature measuring hole is as close to the welding surface as possible.
Preferably, the temperature sensing contact of the K-type thermocouple is inserted into the temperature measuring hole for fixation.
Preferably, the parameters of the ultrasonic welding in the third step are as follows: the welding energy is 500-2000J, the welding amplitude is 9-13 mu m, the welding pressure is 0.3-0.5MPa, and the welding frequency is 20kHz.
Post-weld test analysis step: and (3) carrying out qualitative and quantitative analysis on microstructure components at the joint interface by using SEM+EDS+XRD, carrying out online acquisition on an interface thermal cycle curve by using a K-type thermocouple, and finally measuring the joint shearing performance by using a universal test stretcher.
Compared with the prior art, the invention has the beneficial effects that:
1. the addition of Zn foil as a welded joint of the intermediate layer can hinder continuous brittle intermetallic compounds (Al 2 Cu) and form a large number of solid solutions and eutectic structures that effectively improve the tensile properties of the joint.
2. Under the same welding process parameters, the Zn foil is added as the welding joint of the middle layer, and the peak temperature of the interface is higher than that of the interface without the middle layer, thereby being more beneficial to the welding process.
Drawings
FIG. 1 is a schematic diagram of Al/Cu ultrasonic welding using Zn foil as an intermediate reaction layer.
FIG. 2 is a graph of the temperature measurement of a K-type thermocouple.
FIG. 3 is a schematic diagram of a Scanning Electron Microscope (SEM) of a dissimilar metal joint in example 1, wherein b is a partial enlarged view of a.
FIG. 4 is a scanning electron microscope image of the dissimilar metal joint of comparative example 1.
Fig. 5 shows XRD diffraction peaks of the aluminum side joint in example 1.
FIG. 6 shows the diffraction peaks of the aluminum side joint in comparative example 1.
FIG. 7 is a thermal cycling curve at the joint interface in example 1.
FIG. 8 is a thermal cycling curve at the joint interface in comparative example 1.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described in the following examples. The specific conditions are not noted in the examples and are carried out according to conventional conditions or conditions recommended by the manufacturer. The reagents or apparatus used were conventional products commercially available without the manufacturer's attention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.
Example 1
An Al/Cu ultrasonic welding method taking Zn foil as an intermediate reaction layer, wherein a welding parent metal is respectively selected from 7075-T6 aluminum alloy plates and T2 copper-clad plates, the specification is 50 x 15 x 1mm, a pure Zn foil is selected as an intermediate layer, and the specification is 15 x 0.05mm, and the method comprises the following steps:
(1) And (3) a surface treatment step. And (3) polishing surface oxides of the copper plate and the aluminum alloy plate by adopting 800-mesh metallographic sand paper, polishing the oxides on the surface of the Zn foil by adopting 2000-mesh metallographic sand paper, immersing the polished material to be welded into absolute ethanol solution completely, ultrasonically cleaning for 5 minutes to remove oil stains and impurities on the surface, and finally drying the material to be welded by using a blower.
(2) And a clamp fixing step. The method comprises the steps of arranging Zn foils at the interface of two base materials to be welded in a lap joint mode of 'copper up and aluminum down', wherein lap joint amount is 35 mm, and fixing the Zn foils on a welding base fixture after assembly of the components to be welded is completed so as to ensure that the components to be welded do not slip.
(3) And (3) arranging a K-type thermocouple. And processing a temperature measuring hole with the diameter of 1mm on the surface of the red copper plate, enabling the depth of the temperature measuring hole to be as close to the position of the interface to be welded as possible, and then inserting and fixing the temperature sensing contact of the K-type thermocouple into the temperature measuring hole.
(4) And (3) parameter adjustment welding: the welding parameters of the welding machine are set as follows: the welding energy is 1500J, the welding amplitude is 9 mu m, the welding pressure is 0.4MPa, the welding frequency is 20kHz, the ultrasonic welding is carried out, and the natural cooling is carried out after the welding is finished.
(5) Post-weld test analysis step: and (3) carrying out qualitative and quantitative analysis on microstructure components at the joint interface by using SEM+EDS+XRD, carrying out online acquisition on an interface thermal cycle curve by using a K-type thermocouple, and finally measuring the joint shearing performance by using a universal test stretcher.
Comparative example 1
An Al/Cu ultrasonic welding method without an intermediate reaction layer is provided, wherein 7075-T6 aluminum alloy plates and T2 copper-clad plates are respectively selected as welding base materials, the specification is 50 x 15 x 1mm, and the method comprises the following steps:
(1) And (3) a surface treatment step. And (3) polishing surface oxides of the copper plate and the aluminum alloy plate by adopting 800-mesh metallographic abrasive paper, completely immersing the polished material to be welded into absolute ethanol solution, ultrasonically cleaning for 5 minutes to remove oil stains and impurities on the surface, and finally drying the material to be welded by using a blower.
(2) And a clamp fixing step. The base metal to be welded adopts a lap joint mode of 'copper up and aluminum down', the lap joint amount is 35 x 15mm, and after the assembly of the component to be welded is completed, the component to be welded is fixed on a welding base clamp so as to ensure that the component to be welded does not slide.
(3) And (3) arranging a K-type thermocouple. And processing a temperature measuring hole with the diameter of 1mm on the surface of the red copper plate, enabling the depth of the temperature measuring hole to be as close to the position of the interface to be welded as possible, and then inserting and fixing the temperature sensing contact of the K-type thermocouple into the temperature measuring hole.
(4) And (3) parameter adjustment welding: the welding parameters of the welding machine are set as follows: the welding energy is 1500J, the welding amplitude is 9 mu m, the welding pressure is 0.4MPa, the welding frequency is 20kHz, the ultrasonic welding is carried out, and the natural cooling is carried out after the welding is finished.
(5) Post-weld test analysis step: and (3) carrying out qualitative and quantitative analysis on microstructure components at the joint interface by using SEM+EDS+XRD, carrying out online acquisition on an interface thermal cycle curve by using a K-type thermocouple, and finally measuring the joint shearing performance by using a universal test stretcher.
Analysis of results
FIG. 3 is a cross-sectional scanning electron microscope image of a dissimilar metal joint obtained by an Al/Cu ultrasonic welding method using Zn foil as an intermediate reaction layer in example 1 of the present invention; FIG. 4 is a cross-sectional scanning electron microscope image of a dissimilar metal joint obtained by the Al/Cu ultrasonic welding method without an intermediate reaction layer added in comparative example 1. As can be seen from fig. 3 and 4, the dissimilar metal joint obtained in example 1 is mainly composed of a small amount of black particulate matter, a white spherical matter and a large amount of lamellar eutectic structure; the dissimilar metal joint obtained in comparative example 1 formed an intermetallic compound layer 2.3 μm thick.
Fig. 5 shows XRD test results of aluminum side joint obtained by the Al/Cu ultrasonic welding method using Zn foil as an intermediate reaction layer in example 1 of the present invention, fig. 6 shows XRD test results of aluminum side joint obtained by the Al/Cu ultrasonic welding method without an intermediate reaction layer added in comparative example 1, and table 1 shows chemical element compositions of each point in fig. 3 and 4. From the combination analysis of fig. 5 and 6 with table 1, it can be confirmed that the black granular matters in the heterogold obtained in example 1 are Al-based solid solutions, the white spherical matters are Zn, the lamellar structures are Al-Zn eutectic structures, wherein the granular Al-based solid solutions are mainly precipitated in the solidification process and are dispersed in the Al-Zn eutectic structures under the ultrasonic action, and the solid solutions and the eutectic structures can effectively improve the joint performance, and in addition, no brittle intermetallic compound is generated at the interface; while the dissimilar metal joint obtained in comparative example 1 was internally formedIs Al 2 Cu, a brittle intermetallic compound, is a root cause of deterioration of joint performance.
TABLE 1
Position of Al (atomic percent) Cu (atomic percent) Zn (atomic percent) Phase (C)
A 32.73 3.48 63.79 Al-based solid solution
B 19.18 2.75 78.06 Al-Zn eutectic
C 4.06 2.59 93.35 Zn
D 69.81 30.19 0 Al 2 Cu
FIG. 7 is a thermal cycle curve at the interface of a dissimilar metal joint obtained by the Al/Cu ultrasonic welding method using Zn foil as an intermediate reaction layer in example 1 of the present invention; FIG. 8 is a thermal cycle curve at the interface of a dissimilar metal joint obtained by the Al/Cu ultrasonic welding method without an intermediate reaction layer added in comparative example 1. As can be seen from fig. 7 and 8, the peak temperature of the interface in example 1 is 431.7 ℃, the eutectic reaction temperature of aluminum and zinc (382 ℃) has been reached, and the interface forming mechanism is similar to brazing; the peak temperature of the interface in comparative example 1 is 346 ℃ and is far less than the eutectic reaction temperature point of aluminum and copper, and the forming mechanism of the interface is mainly solid phase welding based on interatomic diffusion. In summary, the higher the interface temperature, the faster the interatomic diffusion speed, the stronger the plastic flow ability of the metal and the better the welding effect.
Table 2 shows the tensile properties of the joints obtained in inventive example 1 and comparative example 1, and it can be seen that the addition of Zn interlayer at the Al/Cu interface significantly improved the tensile strength of the joint, and that the shear force of the joint with Zn layer was improved by 43.9% as compared with that without addition.
TABLE 2
Tensile test specimen Shear force (N)
Example 1 2480
Comparative example 1 1724
The embodiments described above represent only a few preferred embodiments of the present invention, which are described in more detail and are not intended to limit the present invention. It should be noted that various changes and modifications can be made to the present invention by those skilled in the art, and any modifications, equivalent substitutions, improvements, etc. which are within the spirit and principle of the present invention are included in the scope of the present invention.

Claims (6)

1. An Al/Cu ultrasonic welding method taking Zn foil as an intermediate reaction layer is characterized by comprising the following steps:
step one: performing surface treatment on an aluminum alloy plate, a copper plate and a Zn foil for standby;
step two: overlapping the treated aluminum alloy plate and the treated copper plate in a lap joint mode of 'copper on aluminum down', and placing Zn foil at the interface between the aluminum alloy plate and the copper plate to be welded for fixation;
step three: and (3) performing ultrasonic welding on the piece to be welded obtained in the step two, and cooling to obtain the product.
2. The method for ultrasonic welding of Al/Cu with Zn foil as an intermediate reaction layer according to claim 1, wherein in the step one, the aluminum alloy is 7075-T6 aluminum alloy, and the red copper is T2 red copper.
3. The method for ultrasonic welding of Al/Cu with Zn foil as an intermediate reaction layer according to claim 1, wherein the first surface treatment is to polish the surface with metallographic sand paper, and finally ultrasonic cleaning is performed by immersing in absolute ethyl alcohol.
4. The Al/Cu ultrasonic welding method using Zn foil as an intermediate reaction layer according to claim 1, wherein the second step further comprises processing temperature measuring holes on the surface of the copper plate, wherein the depth of the temperature measuring holes is as close to the welding surface as possible.
5. The method for Al/Cu ultrasonic welding using Zn foil as an intermediate reaction layer according to claim 4, further comprising inserting a temperature sensing contact of a K-type thermocouple into the temperature measuring hole for fixation.
6. The Al/Cu ultrasonic welding method using Zn foil as an intermediate reaction layer according to claim 1, wherein the parameters of the ultrasonic welding in step three are: the welding energy is 500-2000J, the welding amplitude is 9-13 mu m, the welding pressure is 0.3-0.5MPa, and the welding frequency is 20kHz.
CN202410039356.XA 2024-01-10 2024-01-10 Al/Cu ultrasonic welding method with Zn foil as intermediate reaction layer Pending CN117697114A (en)

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