Improvements in the Microstructure and Mechanical Properties of Aluminium Alloys Using Ultrasonic-Assisted Laser Welding

Experimental and Numerical Investigation of the Use of Ultrasonic Waves to Assist Laser Welding

This study evaluates the enhancement of laser welding using ultrasonic waves aimed at reorganising the intermetallic position in such a fashion that leads to increased mechanical properties of welds in battery pack assemblies for electric vehicles. The experiment employed 20 kHz and 40 kHz High-Power Ultrasound Transducers (HPUTs) in both contact and contactless modes. A simplified experimental configuration is suggested to represent conditions similar to those found in electric vehicle battery pack assemblies. Measurements of vibration transmission to aluminium alloy 1050 plates revealed more than a 1000-fold increase in acceleration amplitude in contact mode compared to contactless mode. The 20 kHz transducer in contactless mode demonstrated superior performance, showing a 10% increase in load and 27% increase in extension compared to welding without ultrasonic assistance. On the other hand, the 40 kHz transducer, while still improved over non-ultrasonic methods, showed less pronounced benefits. This suggests that lower-frequency ultrasonic assistance (20 kHz) is more effective in this specific context. The study explores ultrasonic assistance in laser welding copper (Cu101) to aluminium alloy 1050 using 20 kHz and 40 kHz HPUTs, showing that both transducers enhance microstructural integrity by reducing copper homogenisation into aluminium, with the 20 kHz frequency proving more effective in this context. A numerical simulation was conducted to evaluate the transmission of pressure into the molten pool of the weld, correlated with the vibration results obtained from the 20 kHz transducer. The numerical simulation confirms that no cavitation is initiated in the molten pool area, and all improvements are solely due to the ultrasonic waves.

Analytical Simulation of the Microbubble Collapsing in a Welding Fusion Pool

This paper explains the use of remote ultrasound vibration at the optimum position and frequencies to vibrate plates under welding, with the aim of initiating cavitation in the molten pool area. It has been shown in the literature that ultrasound cavitation changes microstructure morphology and refines the grain of the weld. In practice, the plates are excited through narrow-band high-power ultrasound transducers (HPUTs). Therefore, a theoretical investigation is carried out to identify the plate-mode shapes due to the ultrasound vibration aligned with the frequency bandwidth of HPUTs available in the marketplace. The effect of exciting the plate at different locations and frequencies is studied to find the optimum position and frequencies to achieve the maximum pressure at the area of the fusion zone. It was shown that applying the excitation from the side of the plate produces an order of 103 higher vibration displacement amplitude, compared with excitation from the corner. The forced vibration of cavitation and bursting time are studied to identify vibration amplitude and the time required to generate and implode cavities, hence specifying the vibration-assisted welding time. Thus, the proposed computational platform enables efficient multiparametric analysis of cavitation, initiated by remote ultrasound excitation, in the molten pool under welding.