Ultrasonic metal welding of Al/Cu joints with Ni coating: parametric effects on joint performance and microstructural modifications
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Soumyajit Das
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Bharat Chandra Routara
Abstract
The increasing adoption of lithium-ion battery packs in electric vehicles has sparked considerable interest in choosing the appropriate busbar material and obtaining suitable mechanical, electrical, and thermal properties of the welded joints. This study comprehensively employs ultrasonic metal welding to create tab-to-busbar connections utilizing 0.3 mm nickel-coated copper and 0.5 mm aluminum sheets. Joint mechanical performance, microstructural characterization, and welding mechanism at different weld energies and clamping pressures are studied to understand the material flow, inter-atomic mixing, and newer grain formation phenomena. The correlation between the dynamic characteristics of electrical contact resistance and the resulting temperature is also revealed under various welding conditions by applying current through the joints. The micro-hardness analysis disclosed the different weld zones of distinctive values where the material has been mixed. Further, the nickel coating on the copper surfaces facilitates metallurgical bonding to a significant extent. The results revealed that the inter-atomic diffusion, wave-like bonding area, and micro-bond development on the weld cross-sectional surface are the foremost reasons for satisfactory welds.
Acknowledgments
The authors are truly grateful to the organizer and convenor of ICPCM 2023.
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Research ethics: Not applicable.
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Informed consent: Not applicable.
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Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.
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Use of Large Language Models, AI and Machine Learning Tools: None declared.
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Conflict of interest: The authors state no conflict of interest.
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Research funding: None declared.
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Data availability: Not applicable.
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- News
- DGM – Deutsche Gesellschaft für Materialkunde
Articles in the same Issue
- Frontmatter
- Editorial
- 5th International Conference on Processing and Characterization of Materials 2023 (ICPCM 2023)
- Original Papers
- Experimental studies on coal mine over-burden incorporated concrete as a sustainable substitute for fine aggregate in concrete construction
- A complex impedance spectroscopy study on PVDF/PANI/CoFe2O4 composites
- Optimizing electrical properties and efficiency of copper-doped CdS and CdTe solar cells through advanced ETL and HTL integration: a comprehensive experimental and numerical study
- Synthesis and characterization of hydroxyapatite from Ariidea fish bone as reinforcement material for (chios mastic gum: papyrus vaccine pollen) bio composite bony scaffold
- Optimization of the process parameter of lean-grade self-reducing pellets by surface response modelling
- From raw materials to functional material: synthesis and piezoelectric characterization of PIN–PT binary relaxor material
- Effect of ball milling on bulk MoS2 and the development of Al–MoS2 nanocomposites by powder metallurgy route
- Effect of beeswax on the physico-mechanical properties of poly (butylene adipate terephthalate)/poly lactic acid blend films
- Effect of Y2O3, TiO2, ZrO2 dispersion on oxidation resistance of W–Ni–Nb–Mo alloys
- Multifunctional characterisation of pressureless sintered Al2O3 –CaTiO3 nanocomposite
- Silicon–carbon superhydrophobic nano-structure for next generation semiconductor industry
- Interrelation between mechanical and electromagnetic radiation emission parameters with variable notch-width ratios under tensile fracture in silicon steel
- Effect of tool rotation and welding speed on microstructural and mechanical properties of dissimilar AA6061-T6 and AA5083-H12 joint in friction stir welding
- Effect of bentonite and molasses binder content on physical and mechanical properties of green and fired mill scale pellets
- FA-GGBFS based geopolymer concrete incorporating CMRW and SS as fine and coarse aggregates
- Characteristic study of intra woven green fibers for structural application
- An experimental investigation by electrochemical impedance spectroscopy for the study of mechanism of copper electrodeposition from an acidic bath
- Bažant-Le-Kirane Paradox of fatigue failure in engineering materials
- Thermal modeling and analysis of laser transmission welding of polypropylene: process mechanics and parameters
- The influence of welding modes on metallic structures processed through WAAM
- Ultrasonic metal welding of Al/Cu joints with Ni coating: parametric effects on joint performance and microstructural modifications
- News
- DGM – Deutsche Gesellschaft für Materialkunde
