Power consumption and friction coefficient in the ultrasonic consolidation of aluminium alloys

Abstract

Energy input and friction behaviour are two of the key phenomena related with the welding bond of ultrasonic consolidation (UC) process. In this study, the effects of welding parameters, such as the building height, travel speed, oscillation amplitude and applied force, on the power consumption of the horn and friction coefficient of the welding interface of UC are investigated for aluminium alloys 2024 and 7075. Multiple regression equations are developed to estimate the power consumption and friction coefficient using the welding parameters. A line-contact friction test is performed to examine the friction coefficient of UC under the various applied forces and preheating temperatures. The quantitative relationships among the welding parameters, friction coefficient and power consumption are derived.