Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and Design

Ultrasonic welding of titanium alloy Ti6Al4V to carbon fibre reinforced polymer (CFRP) at 20 kHz frequency requires suitable welding tools, so called sonotrodes. The basic function of ultrasonic welding sonotrodes is to oscillate with displacement amplitudes typically up to 50 µm at frequencies clos...

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Main Authors: Moritz Liesegang, Yuan Yu, Tilmann Beck, Frank Balle
Format: Article
Language:English
Published: MDPI AG 2021-06-01
Series:Journal of Manufacturing and Materials Processing
Subjects:
Online Access:https://www.mdpi.com/2504-4494/5/2/61
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spelling doaj-1dc96d5847524118a238eb4044b26ea72021-07-01T00:04:02ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942021-06-015616110.3390/jmmp5020061Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and DesignMoritz Liesegang0Yuan Yu1Tilmann Beck2Frank Balle3Institute of Materials Science and Engineering, Technische Universität Kaiserslautern, 67653 Kaiserslautern, GermanyInstitute of Materials Science and Engineering, Technische Universität Kaiserslautern, 67653 Kaiserslautern, GermanyInstitute of Materials Science and Engineering, Technische Universität Kaiserslautern, 67653 Kaiserslautern, GermanyWalter-and-Ingeborg-Herrmann Chair for Power Ultrasonics and Engineering of Functional Materials, Department of Sustainable Systems Engineering (INATECH), Faculty of Engineering, University of Freiburg, 79110 Freiburg, GermanyUltrasonic welding of titanium alloy Ti6Al4V to carbon fibre reinforced polymer (CFRP) at 20 kHz frequency requires suitable welding tools, so called sonotrodes. The basic function of ultrasonic welding sonotrodes is to oscillate with displacement amplitudes typically up to 50 µm at frequencies close to the eigenfrequency of the oscillation unit. Material properties, the geometry of the sonotrode, and the sonotrode tip topography together determine the longevity of the sonotrode. Durable sonotrodes for ultrasonic welding of high-strength joining partners, e.g., titanium alloys, have not been investigated so far. In this paper, finite element simulations were used to establish a suitable design assuring the oscillation of a longitudinal eigenmode at the operation frequency of the welding machine and to calculate local mechanical stresses. The primary aim of this work is to design a sonotrode that can be used to join high-strength materials such as Ti6Al4V by ultrasonic welding considering the longevity of the welding tools and high-strength joints. Material, sonotrode geometry, and sonotrode tip topography were designed and investigated experimentally to identify the most promising sonotrode design for continuous ultrasonic welding of Ti6AlV4 and CFRP. Eigenfrequency and modal shape were measured in order to examine the reliability of the calculations and to compare the performance of all investigated sonotrodes.https://www.mdpi.com/2504-4494/5/2/61ultrasonic weldingsonotrodeshybrid joiningmodal analysistitanium/CFRPmulti-material-design
collection DOAJ
language English
format Article
sources DOAJ
author Moritz Liesegang
Yuan Yu
Tilmann Beck
Frank Balle
spellingShingle Moritz Liesegang
Yuan Yu
Tilmann Beck
Frank Balle
Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and Design
Journal of Manufacturing and Materials Processing
ultrasonic welding
sonotrodes
hybrid joining
modal analysis
titanium/CFRP
multi-material-design
author_facet Moritz Liesegang
Yuan Yu
Tilmann Beck
Frank Balle
author_sort Moritz Liesegang
title Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and Design
title_short Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and Design
title_full Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and Design
title_fullStr Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and Design
title_full_unstemmed Sonotrodes for Ultrasonic Welding of Titanium/CFRP-Joints—Materials Selection and Design
title_sort sonotrodes for ultrasonic welding of titanium/cfrp-joints—materials selection and design
publisher MDPI AG
series Journal of Manufacturing and Materials Processing
issn 2504-4494
publishDate 2021-06-01
description Ultrasonic welding of titanium alloy Ti6Al4V to carbon fibre reinforced polymer (CFRP) at 20 kHz frequency requires suitable welding tools, so called sonotrodes. The basic function of ultrasonic welding sonotrodes is to oscillate with displacement amplitudes typically up to 50 µm at frequencies close to the eigenfrequency of the oscillation unit. Material properties, the geometry of the sonotrode, and the sonotrode tip topography together determine the longevity of the sonotrode. Durable sonotrodes for ultrasonic welding of high-strength joining partners, e.g., titanium alloys, have not been investigated so far. In this paper, finite element simulations were used to establish a suitable design assuring the oscillation of a longitudinal eigenmode at the operation frequency of the welding machine and to calculate local mechanical stresses. The primary aim of this work is to design a sonotrode that can be used to join high-strength materials such as Ti6Al4V by ultrasonic welding considering the longevity of the welding tools and high-strength joints. Material, sonotrode geometry, and sonotrode tip topography were designed and investigated experimentally to identify the most promising sonotrode design for continuous ultrasonic welding of Ti6AlV4 and CFRP. Eigenfrequency and modal shape were measured in order to examine the reliability of the calculations and to compare the performance of all investigated sonotrodes.
topic ultrasonic welding
sonotrodes
hybrid joining
modal analysis
titanium/CFRP
multi-material-design
url https://www.mdpi.com/2504-4494/5/2/61
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AT yuanyu sonotrodesforultrasonicweldingoftitaniumcfrpjointsmaterialsselectionanddesign
AT tilmannbeck sonotrodesforultrasonicweldingoftitaniumcfrpjointsmaterialsselectionanddesign
AT frankballe sonotrodesforultrasonicweldingoftitaniumcfrpjointsmaterialsselectionanddesign
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