Ultrasonic-assisted welding is one of the most important applications of power ultrasound. The unique physico-chemical effects of ultrasound have been successfully used to change or improve many traditional welding processes, and to solve some insurmountable problems for conventional welding methods. Therefore, this novel technology has a wide potential application in manufacturing industries. However, the current research in this area is mainly focused on the technology results, while the understanding with regards to the interaction mechanism of the ultrasound energy and the welding energy and the level the welding method deserves, is still far from sufficient. In this paper, the characteristics and achievements of ultrasonic-assisted welding, e.g. ultrasonic-assisted arc welding, ultrasonic assisted friction stir welding and ultrasonic assisted brazing, are overviewed. Fundamental phenomena in the ultrasonic field during the welding are summarized, such as the solidification behavior of liquid alloys, rheology and deformation behavior of solid alloys, and interfacial reaction between the liquid brazing alloys and the substrate. Based on this, the main scientific issues of the current research and the suggestion on the research areas to be focused in the future are put forward. It is expected to provide a valuable reference for the fundamental research and engineering applications in this field.
YAN Jiuchun
,
YANG Chunli
,
LIU Huijie
,
CUI Wei
,
XIE Weifeng
,
GUO Weibing
. Overview on Ultrasonic-assisted Welding and Its Scientific Issues#br#[J]. Journal of Mechanical Engineering, 2015
, 51(24)
: 41
-49
.
DOI: 10.3901/JME.2015.24.041
[1] 周丽平，张泉，孙志峻. 直线超声电动机驱动的平面3-PRR并联平台视觉精密定位[J]. 机械工程学报，2014，50(19)：18-23. ZHOU Liping，ZHANG Quan，SUN Zhijun. Precision positioning of a 3-PRR planar parallel manipulator driven by linear ultrasonic motors based on machine vision[J]. Journal of Mechanical Engineering，2014，50(19)：18-23.
[2] 李勋，张德远. 不分离型超声椭圆振动切削试验研究[J]. 机械工程学报，2010，46(19)：177-182. LI Xun，ZHANG Deyuan. Experimental study on the unseparated ultrasonic elliptical vibration cutting[J]. Journal of Mechanical Engineering，2010，46(19)：177-182.
[3] 郐吉才. 在线电解修锐-超声珩磨系统多场耦合机理[J]. 机械工程学报，2014，50(13)：196-201. KUAI Jicai. Coupling mechanisms of electrolytic in process dressing-ultrasonic honing system by multiphisics code[J]. Journal of Mechanical Engineering，2014，50(13)：196-201.
[4] 朱有利，王燕礼，边飞龙，等. 金属材料超声表面强化技术的研究与应用进展[J]. 机械工程学报，2014，50(20)：35-45.ZHU Youli，WANG Yanli，BIAN Feilong，et al. Progresses on research and application of metal ultrasonic surface enhancement technologies[J]. Journal of Mechanical Engineering，2014，50(20)：35-45.
[5] 李晓谦，陈铭，赵世琏，等. 功率超声对7050铝合金除气净化作用的试验研究[J]. 机械工程学报，2010，46(18)：41-45.LI Xiaoqian，CHEN Ming，ZHAO Shilian，et al. Experimental research on the effect of power ultrasonic on the degassing process of 7050 aluminum melts[J]. Journal of Mechanical Engineering，2010，46(18)：41-45.
[6] 袁易全. 近代超声原理及应用[M]. 南京：南京大学出版社，1996. YUAN Yiquan. Principle and application of modern ultrasonic[M]. Nanjing：Nanjing University Press，1996.
[7] KOZLOV A V，ELITSER S I. Kinetics of the acoustoplastic effect[J]. Materials Science and Engineering A，1991，131：17-25.
[8] DAI W L. Effects of high-intensity ultrasonic-wave emission on the weldability of aluminum alloy 7075-T6[J]. Materials Letters，2003，57(16)：2447-2454.
[9] CUI Y，XU C L，HAN Q. Effect of ultrasonic vibration on unmixed zone formation[J]. Scripta Materialia，2006，55(11)：975-978.
[10] WATANABE T，SHIROKI M，YANAGISAWA A，et al. Improvement of mechanical properties of ferritic stainless steel weld metal by ultrasonic vibration[J]. Journal of Materials Processing Technology，2010，210(12)：1646-1651.
[11] MAZZOLA M S，MOLEN G M. Modeling of a DC glow plasma loudspeaker[J]. The Journal of the Acoustical Society of America，1987，81(6)：1972-1978.
[12] 吴敏生，段向阳. 电弧超声的激发及其特性研究[J]. 清华大学学报，1999，39(6)：110-112.WU Minsheng，DUAN Xiangyang. Study of arc ultrasonic excitation and its characteristics[J]. Journal of Tsinghua University，1999，39(6)：110-112.
[13] 吴敏生，何龙标，李路明，等. 电弧超声焊接技术[J]. 焊接学报，2005，26(6)：40-44. WU Minsheng，HE Longbiao，LI Luming，et al. Arc-ultrasonic welding technology[J]. Transactions of the China Welding Institution，2005，26(6)：40-44.
[14] 齐铂金，许海鹰，张伟. 0Cr18Ni9Ti 超音频脉冲TIG焊接头组织与性能[J]. 北京航空航天大学学报，2009(2)：132-136.QI Bojin，XU Haiying，ZHANG Wei. Microstructure and property analysis of 0Cr18Ni9Ti joints welded by ultrasonic pulse tungsten-inert-gas welding technology[J]. Journal of Beijing University of Aeronautics and Astronautics，2009(2)：132-136.
[15] 王建军，林涛. 电弧超声激励共熔池双钨极氩弧焊接方法[J]. 上海交通大学学报，2011，45(1)：15-18.WANG Jianjun，LIN Tao. Twin-arc TIG welding with ultrasonic excitation[J]. Journal of Shanghai Jiaotong University，2011，45(1)：15-18.
[16] MORISADA Y，FUJII H，INAGAKI F，et al. Development of high frequency tungsten inert gas welding method[J]. Materials & Design，2013，44：12-16.
[17] 孙清洁. 超声-TIG电弧复合焊接方法及电弧行为研究[D]. 哈尔滨：哈尔滨工业大学，2010.SUN Qingjie. Research on ultrasonic-arc behaviors and ultrasonic assisted TIG welding method[D]. Harbin：Harbin Institute of Technology，2010.
[18] YUAN H R，LIN S B，YANG C L，et al. Microstructure and porosity analysis in ultrasonic assisted TIG welding of 2014 aluminum alloy[J]. China Welding，2011，20(1)：39-43.
[19] FAN C L，YANG C L，LIN S B，et al. Arc character of the ultrasonic-wave assisted GMAW[J]. Welding Journal，2013，91(12)：375-380.
[20] NOLTINGK B E，NEPPIRAS E A. Ultrasonic soldering irons[J]. Journal of Scientific Instruments，1951，28(2)：50-52.
[21] CIALONE J H. Ultrasonic soldering and brazing[J]. EWI Insight，2007，20：4-5.
[22] TERRILL J R，DZIERSKI S F. Fluxless ultrasonic soldering of aluminum tubes. U.S. Patent 3680200[P]. 1972-08-01.
[23] WATANABE T，ADACHI H，YANAGISAWA A. Brazing of A5056 aluminium alloy with the aid of ultrasonic vibration using Ag filler metal[J]. Welding International，2010，24(3)：176-181.
[24] FARIDI H R，DEVLETIAN J H，LE H. A new look at flux-free ultrasonic soldering[J]. Welding Journal，2000，79(9)：41-45.
[25] 闫久春，吕世雄，许志武，等. 铝基复合材料液相振动焊接方法：中国，ZL03111099. 1[P]. 2005-10-26.YAN Jiuchun，LÜ Shixiong，XU Zhiwu，et al. Vibration welding of aluminum matrix composites in liquid phase：China，ZL03111099. 1[P]. 2005-10-26.
[26] WIELAGE B，HOYER I，WEIS S. Soldering aluminum matrix composites[J]. Welding Journal，2007，86(3)：67-70.
[27] ELREFAEY A，WOJARSKI L，PFEIFFER J，et al. Preliminary investigation on ultrasonic-assisted brazing of titanium and titanium/stainless steel joints[J]. Welding Journal，2013，92：148-153.
[28] XIAO Y，JI H J，LI M Y，et al. Microstructure and joint properties of ultrasonically brazed Al alloy joints using a Zn-Al hypereutectic filler metal[J]. Materials & Design，2013，47：717-724.
[29] NAGAOKA T，MORISADA Y，FUKUSUMI M，et al. Strength and corrosion resistance of a solder joint in ultrasonic soldering of aluminium using quasi-melting solder[J]. Welding International，2009，23(12)：879-885.
[30] 贺地求，李剑，李东辉，等. 铝合金超声搅拌复合焊接[J]. 焊接学报，2011，32(12)：70-72,108. HE Diqiu，LI Jian，LI Donghui，et al. Study on ultrasonic stir hybrid welding of aluminum alloy[J]. Transactions of the China Welding Institution，2011，32(12)：70-72,108.
[31] 贺地求，彭建红，杨坤玉，等. 航空铝合金超声搅拌复合焊工艺及机理[J]. 中国有色金属学报，2012，22(10)：2744-2748.HE Diqiu，PENG Jianhong，YANG Kunyu，et al. Technology and mechanism of ultrasonic stir compound welding of aeronautical aluminum alloy[J]. The Chinese Journal of Nonferrous Metal，2012，22(10)：2744-2748.
[32] 刘小超，武传松. 超声振动对6061-T4铝合金搅拌摩擦焊接头组织和性能的影响[J]. 焊接学报，2014，35(1)：49-53. LIU Xiaochao，WU Chuansong. Effect of ultrasonic vibration on microstructure and mechanical properties of friction stir welded 6061-T4 aluminum alloy[J]. Transactions of the China Welding Institution，2014，35(1)：49-53.
[33] LIU Xiaochao，WU Chuansong，MICHAEL R. Mechanical properties of 2024-T4 aluminum alloy joint in ultrasonic vibration enhanced friction stir welding[J]. China Welding，2013，22(4)：8-13.
[34] PARK K. Development and analysis of ultrasonic assisted friction stir welding[D]. Michigan：University of Michigan，2009.
[35] 陈晓光. SiC陶瓷与Ti-6Al-4V合金超声波辅助钎焊的润湿结合机制及工艺研究[D]. 哈尔滨：哈尔滨工业大学，2013.CHEN Xiaoguang. Mechanisms for wetting and bonding of ultrasonic assisted brazed SiC ceramic and Ti-6Al-4V alloy and their brazing process[D]. Harbin：Harbin Institute of Technology，2013.
[36] 许志武. 铝基复合材料超声辅助钎焊的润湿及钎缝复合化机理[D]. 哈尔滨：哈尔滨工业大学，2008.XU Zhiwu. Mechanisms for ultrasonic assisted wetting and bonding of aluminum based composites by liquid filler and their applications[D]. Harbin：Harbin Institute of Technology，2008.
[37] 李远星. 2024Al超声波辅助软钎焊工艺及连接界面接合机制[D]. 哈尔滨：哈尔滨工业大学，2012.LI Yuanxing. Mechanism of interfacial bonding And Soldering process assisted by ultrasound of 2024 Al Joint[D]. Harbin：Harbin Institute of Technology，2012.
[38] HAFEZ K M，NAKA M. Mechanism of ultrasonic irradiation on joining of alumina/copper[J]. Transactions of JWRI，2002，31(2)：177-180.
[39] WATANABE T，YANAGISAWA A，FURUKAWA A，et al. Soldering of Al-Mg alloy with the aid of ultrasonic vibration[J]. Quarterly Journal of Japan Welding Society，1993，11(4)：484-489.
[40] NAGAOKA T，MORISADA Y，FUKUSUMI M，et al. Selection of soldering temperature for ultrasonic-assisted soldering of 5056 aluminum alloy using Zn-Al system solders[J]. Journal of Materials Processing Technology，2011，211(9)：1534-1539.
[41] 张洋，闫久春. SiCp/A356复合材料超声波辅助钎焊[J]. 焊接学报，2008，30(3)：1-4.ZHANG Yang，YAN Jiuchun. Ultrasonically aided brazing of SiCp/A356 composites[J]. Transactions of the China Welding Institution，2008，30(3)：1-4.
[42] NAGAOKA T，MORISADA Y，FUKUSUMI M，et al. Joint strength of aluminum ultrasonic soldered under liquidus temperature of Sn-Zn hypereutectic solder[J]. Journal of Materials Processing Technology，2009，209(11)：5054-5059.
[43] 高晨，李红，栗卓新. AZ31B镁合金超声振动钎焊接头微观结构和力学性能[J]. 焊接学报，2009，30(2)：129-132.GAO Chen，LI Hong，LI Zhuoxin. Microstructure and mechanical property of ultrasonic soldered joint of AZ31B magnesium alloys[J]. Transactions of the China Welding Institution，2009，30(2)：129-132.
[44] WIELAGE B，MUECKLICH S. Improving the soldering of magnesium alloys[J]. Welding Journal，2006，85(9)：48-51.
[45] EL-SAYED M H，NAKA M. Structure and properties of carbon steel-aluminum dissimilar joints[J]. Science and Technology of Welding & Joining，2005，10(1)：27-31.
[46] EL-SAYED M H，HAFEZ K M，NAKA M. Interfacial structure and bond strength of ultrasonic brazed Al-304 stainless steel dissimilar joints[J]. Science and Technology of Welding & Joining，2004，9(6)：560-564.
[47] 魏晶慧. Fe36Ni合金与SiC/Al复合材料超声波钎焊的界面结构形成机制及接头性能研究[D]. 哈尔滨：哈尔滨工业大学，2013.WEI Jinghui. Interfacial microstructure and formation mechanism on ultrasonic soldering of Fe36Ni alloy and SiC/Al composites[D]. Harbin：Harbin Institute of Technology，2013.
[48] XIAO Y，JI H J，LI M Y，et al. Ultrasound-assisted brazing of Cu/Al dissimilar metals using a Zn-3Al filler metal[J]. Materials & Design，2013，52：740-747.
[49] EL-SAYED M H. Ultrasonic brazing of copper to aluminum[J]. Canadian Metallurgical Quarterly，2004，43(1)：117-124.
[50] MA Z P，ZHAO W W，YAN J C，et al. Interfacial reaction of intermetallic compounds of ultrasonic-assisted brazed joints between dissimilar alloys of Ti-6Al-4V and Al-4Cu-1Mg[J]. Ultrasonics Sonochemistry，2011，18(5)：1062-1067.
