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Design and Experimental Concept for Dissimilar Ultrasonic Welding

Joints for Aluminum Alloy to Glass-Fiber-Reinforced Polymer Tubes

Michael de Leon1*, Mark Angelo Diaz2, Richard Pascua3, and Gellieca Dullas4
*email: [email protected]

Abstract

This conceptual study explores ultrasonic welding (UW) for creating joints
between aluminum alloy A5052-H32 and glass-fiber-reinforced polymer (GFRP)
cylindrical tubes, capitalizing on the method's advantages, such as low energy
requirements, minimal heat-affected zones, and direct energy transfer to the weld
interface. The research, conducted by the group with extensive expertise in solid-
state joining and material deformation under extreme conditions, responds to the
growing demand for reliable, fast, and cost-effective joining technologies. The
proposed hybrid-UW technique introduces gradient functions at the joint interface,
aiming to enhance the performance of Al/GFRP dissimilar joints. The manuscript not
only outlines the technical approach and experimental methods employed but also
highlights the distinctive aspects of the proposed technology. In addition to detailing
the materials used and the design considerations for the ultrasonic welder's horn and
anvil, the study provides a glimpse into the practical implementation of the
proposed hybrid- UW technique. The limited joints made during the experimental
phase serve as a proof-of-concept for the feasibility and potential effectiveness of the
approach.

Keywords: Ultrasonic welding, Dissimilar joints, Aluminum alloy, Glass-fiber-reinforced

polymers, Hybrid ultrasonic welding, Joint interface, Lightweight materials, Joining
technology.
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Introduction
The demand for innovative joining technologies capable of joining dissimilar
materials with varying properties has surged recently. Lightweight aluminum alloys,
known for their structural advantages, and glass-fiber-reinforced polymer (GFRP)
composites, prized for their high strength-to-weight ratio, present a compelling
combination for diverse industrial applications. Joining these materials, however,
remains a challenge, and it is this challenge that motivated the current study. This
research is based on a comprehensive understanding of solid-state joining techniques,
with a particular emphasis on ultrasonic welding (UW). The process of joining
materials without the fusion of heat aligns seamlessly with the group's expertise (Shin
et al., 2016). Over the years, the researchers have significantly contributed to the field,
exploring various materials' deformation behaviors and developing novel joining
techniques under extreme conditions (Shin et al., 2008; Shin & Jung, 2008; Shin, 2014,
Shin & De Leon, 2015, Shin & De Leon, 2017, Chen et al., 2016). These conditions
include high velocity and pressure, cryogenic temperatures, mechanical property
testing, and high current conditions, making the researchers’ experience different
from the conventional studies in the field.
The industry's pressing need for dependable, efficient, and reasonably priced
joining technologies designed for construction including fiber-reinforced polymer
materials is what encouraged this research. Although mechanical joining techniques
such as clinching (Zhang et al., 2016) and self-pierce riveting (Mandel & Krüger, 2012;
Lambiase & Ko, 2017) facilitate quick assembly without requiring initial hole drilling
(Ucsnik et al., 2010), the problem is that fasteners are prone to corrosion and their mass
adds structural weight (Tan et al., 2015; Huang et al., 2013). On the contrary, adhesive
bonding has disadvantages such as expensive costs, careful surface preparation, and
long cure times even though it works well (Farahani & Dubé, 2017; Lionetto et al.,
2017). Appropriate adhesion qualities are dependent on a temperature- and time-
controlled crosslinking process (Arenas et al., 2013). Moreover, there are
disadvantages to this technology, including the short lifespan of adhesive joints and
the release of hazardous compounds into the environment (Lambiase et al., 2016;
Pramanik et al., 2017).
Current research worldwide is addressing this need, but the group's advantage
lies in the researchers’ experience in solid-state joining, especially with dissimilar
materials. Ultrasonic welding, chosen as the primary approach, offers distinct
advantages, such as low welding energy requirements and minimal heat-affected
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zones (Shin & De Leon, 2017). In contrast to other techniques like resistance spot
welding, UW and its hybrid variations possibly avoided the liquid phase reactions
and directed energy precisely onto the weld interface (De Leon & Shin, 2017; De Leon
& Shin, 2023; De Leon & Shin, 2022). This study builds upon the researchers’ extensive
knowledge and skills gained for several decades in the deformation behaviors of
materials and the development of joining techniques under extreme conditions. The
integration of ultrasonic welding into the group, extending even to the joining of high-
temperature superconducting tapes, showcases the versatility of this technique (Shin
et al., 2016; De Leon & Shin, 2020; Shin et al., 2020). The researchers’ past contributions,
such as investigations into dissimilar friction stir spot welding of metallic glass to
lightweight crystalline metals (Shin, 2014) and ultrasonic spot welding of A5052-H32
alloy sheets (Shin & De Leon, 2017), mark steps towards addressing similar challenges.
The current study, however, distinguishes itself by investigating the intricate details
of ultrasonic welding joints between aluminum alloys and GFRP composites.
The remaining sections of this manuscript will present the technical approach,
methods, and experimental, and future industry integration of the study, offering a
comprehensive exploration of dissimilar ultrasonic welding joints for aluminum alloy
to GFRP tubes. Through this study, the researchers aim to present not only a novel
contribution to the field but also a potential breakthrough for industrial applications
in the near future.

Methods
The materials selected for these dissimilar UW joints are aluminum alloy
(A5052-H32) and GFRP cylindrical tubes. The two primary components, aluminum,
and GFRP, represent contrasting yet complementary elements in the structural
landscape. The A5052-H32 is chosen for its lightweight properties and favorable
mechanical characteristics, and serves as a critical element in the study. Typically
provided in coupon-type sheets or cap-structured forms with a thickness not
exceeding 2 mm, this alloy exemplifies the type of lightweight materials commonly
used in various industrial applications, particularly in the automotive sector for its
balance of strength and weight.

The GFRP material takes the form of cylindrical tubes with an internal diameter
ranging from 50 mm to 300 mm and a thickness of less than 2 mm. Figure 1 shows the
joint concept between these two materials. The joining positions are also indicated in
Figure 1 as point A and point B. This configuration mirrors real-world structures,
allowing for a representative study of joints that might be encountered in practical
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applications. The GFRP, characterized by its enhanced strength through the

incorporation of glass fibers, brings a dimension of versatility to the joint
configurations, encapsulating the aluminum coupons.

Figure 1. Joint assembly between aluminum A5052-H32 and glass-fiber-reinforced

polymer.

The ultrasonic welding process is performed using a specialized ultrasonic

welder, carefully chosen to optimize the joint performance. It is a lateral-drive UW
machine (KORMAX, model KM-2035) in time control mode, capable of generating the
necessary vibratory energy for effective welding. Additional details about this welder
are available elsewhere (Shin & De Leon, 2017). This welder has a single transducer
system, so oscillating motion is generated on only the horn side of the overlapped
sample to be joined. Nevertheless, it has the capability of generating up to 3.5 kW of
power at a frequency of 20 kHz. The equipment allows precise control over the
welding parameters, including frequency, amplitude, and weld duration.

In addition to conventional ultrasonic welding, a hybrid-ultrasonic welding

technique was introduced. This original technology incorporates a gradient function
at the joint interface, enhancing the transversal oscillation in the weld zone. The hybrid
technique involves several modifications and designs, including specialized horn and
anvil configurations, proper mounting, and clamping through a vise tailored for the
joint structure. A horn and anvil with a pyramidal tip pattern were used as shown in
Figure 2(a) and (b), respectively. The vibration direction was applied parallel to the
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surface of the jointed materials. The horn was made of high-speed steel, having
circular and square surface shapes on both ends, which had dimensions of 14 mm
diameter and 12 mm x 12 mm square shape (please see Figure 2a). Figure 2(b) shows
the specially designed anvil with its respective tips and dimensions. The tips’ patterns
were designed according to the dimensions and physical properties of the materials
to be welded through the preliminary test selections and in the researchers’ previous
study (Chen et al., 2016).

Also, appropriate material interlayers are used to provide gradient functions,

and specific pre- and post-processing methods for both samples and joints. The
combination of these factors, along with careful selection of machine parameters and
material properties, is expected to optimize the hybrid effects on joint performance
and quality.

Figure 2. (a) Horn with square and square shape surface and (b) cylindrical-shaped
anvil with radius of curvature of 100 mm. Note: all linear dimensions are in mm.

Result and Discussion

From encapsulating GFRP tubes with A5052-H32 caps to integrating A5052-H32
coupons within GFRP structures, the researchers’ study pursued to optimize the UW
adaptability. Figure 3 shows the cylindrical GFRP- A5052-H32 UW assembly. To
provide a uniform and continuous application of ultrasonic vibration, a rotary
welding positioner is coupled to the welder setup. This can be controlled at different
rotating speeds, making the joint uniform and systematic. By incorporating this
hybrid-ultrasonic welding technique, the researchers elevated the transversal
oscillation within the weld zone. This approach, achieved through meticulous design
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modifications, clamping strategies, and material interlayers, not only optimized joint
performance but opened new doors for dissimilar material bonding.

Figure 3. A customized cylindrical-shaped anvil is utilized coupled with the

samples’ positioner for uniform and continuous application of ultrasonic vibration.

Acknowledging the need for reliable joints, especially in the tensile strength
aspect, coupon-shaped sheets were first tried to join. Figure 4 shows the A5052-H32
and GFRP samples with surface modifications through abrasive polishing (Figure 4a)
and with an Indium sheet, 100 μm in thickness as interlayer (Figure 4b).

Figure 4. (a) Coupon-shaped A5052-H32 and GFRP samples with polished surfaces
and (b) an Indium sheet inserted between the samples as interlayer material.

Two joints with different weld parameters are presented in Figure 5 (a) and (b).
The possibility of joining these two different materials was materialized. At different
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welding parameter conditions, two distinct welds can be observed after the sample
separation, one with a more abrasive joint interface than the other. The use of
interlayer material and varying welding parameters affects the joint interface. By
further adjusting the welding parameters and finely tuning the interlayer material, an
optimized weld can be achieved.

Figure 5. Ultrasonic welded A5052-H32 and GFRP with two different welding
parameters. The images on the right show the joint interface after the joint separation.
(a) welding time of 1.3 s, 80% vibration amplitude, and 4.5 bar of welding pressure.
(b) welding time of 0.7 s, 100% vibration amplitude, and 6.5 bar of welding pressure.

In the initial results, the dissimilar ultrasonic welding joints emerged not just
as a scientific achievement but as a preparation for potential industrial transformation.
The hybrid-ultrasonic welding technique, the adaptability to real-world conditions,
and the vision for future advancements collectively provided the possibilities for
improvement.
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Conclusion and Recommendation

In conclusion to this study, an investigation into dissimilar ultrasonic welding
joints between A5052-H32 and GFRP cylindrical tubes set sights on the future. This
study represents more than an achievement, it aligns with the ongoing evolutionary
trends in manufacturing and joining technologies. As industries evolve towards
lightweight materials and composite structures, the demand for reliable, efficient, and
adaptable joining techniques becomes increasingly in demand. The dissimilar
ultrasonic welding joints presented here could be promising in transforming
industrial practices. With a hybrid-ultrasonic welding technique that enhances joint
properties, these joints could become essential in the assembly of structures crucial to
sectors such as automotive, aerospace, and renewable energy. This study sets the stage
for a future where ultrasonic welding becomes a versatile tool for joining other
dissimilar materials across various industries.

As industries embrace the era of Industry 4.0 (What is Industry 4.0 and how
does it work?), the adaptability of ultrasonic welded joints to automation becomes a
pivotal aspect. The integration of simulation tools for virtual optimization and non-
destructive testing procedures that detect faults early in the welding process foretell a
future where efficiency and quality intertwine. Crucially, the adaptability of
ultrasonic welding in in-line manufacturing assembly suggests reduced setup times,
increased weld productivity, and higher-quality joints. The vision of a manufacturing
process that predicts failures, configures automatically, and adapts to changes
signifies a leap toward a more streamlined and economical industrial future.
Although not presented in this study, the concept of broader mechanical property
testing involving the joints subjected to adaptive vacuums and varying temperatures
could be of importance. Several tests could assess the joints against thermal shock,
vibration, and dynamic loading conditions.

The dissimilar ultrasonic welding joints presented here, with their

performance, adaptability, and potential for automation, symbolize a stepping stone
towards a future where the joining of dissimilar materials is not just a challenge but
an opportunity for innovation. As industries increasingly prioritize efficiency,
sustainability, and adaptability, the techniques developed in this study could become
instrumental. The dissimilar ultrasonic welding joints may well become a cornerstone
in the construction of structures that define the future of industries, ushering in an era
where innovation and practicality converge for the betterment of industrial practices.
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