Computational analysis of the ultrasonic effects on resistance spot welding process
Computational analysis of the ultrasonic effects on resistance spot welding process
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DOI：
10.1016/j.jmapro.2022.06.050
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发表时间：
2022-09-01
影响因子：
6.2
通讯作者：
Zhang，Wei
中科院分区：
文献类型：
--
作者：
Shah，Umair;Liu，Xun;Zhang，Wei
超声波电阻焊（URW）是一种混合焊接工艺，在电阻点焊（RSW）过程中利用原位超声波振动来增加熔核尺寸，增强焊缝机械性能并细化微观结构。尽管实验结果很有希望，但声学效应对 RSW 过程的潜在机制尚不清楚，因为所涉及的相互作用的物理现象很难用直接的实验方法来揭示。在本研究中，开发并验证了铝合金 URW 工艺的三维全耦合电热机械模型，其中基于 RSW 模型从不同角度模拟了超声波对熔核形成和演化的影响。结果表明，URW焊缝中熔核增大是多种超声效应对接触电阻和熔融金属热物理性质的耦合相互作用的结果，这些效应基于表面氧化物的超声辅助断裂、声软化、空化和流动物理现象。
Ultrasonic resistance welding (URW) is a hybrid welding process that utilizes in situ ultrasonic vibration during resistance spot welding (RSW) process to increase nugget size, enhance weld mechanical properties, and refine microstructure. Despite the promising experimental results, the underlying mechanisms of acoustic effects on the RSW process are elusive as the involved interacting physical phenomena can hardly be revealed with direct experimental methods. In this study, a three-dimensional fully coupled electro-thermo-mechanical model of the URW process for aluminum alloys has been developed and validated, where the ultrasonic effect on nugget formation and evolution is simulated from different perspectives based on a RSW model. It shows that the enlarged nugget in URW welds is a result of coupling interactions among multiple ultrasonic effects on contact resistance and molten metal thermophysical properties, which are based on the ultrasonically assisted fracture of surface oxides, acoustic softening, cavitation and streaming physical phenomena.