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View article: Modeling and validation of hydrogen porosity formation in aluminum laser welding
Modeling and validation of hydrogen porosity formation in aluminum laser welding Open
Laser welding is used to weld aluminum alloy 1100 for battery cell manufacturing in the automotive industry. However, these welds can have porosity that can decrease their performance in the battery packs. One type of porosity is gas poros…
View article: A thermo-metallurgical-mechanical model for microstructure evolution in laser-assisted robotic roller forming of ultrahigh strength martensitic steel
A thermo-metallurgical-mechanical model for microstructure evolution in laser-assisted robotic roller forming of ultrahigh strength martensitic steel Open
Funding Information: This research was supported by Science and Technology Commission of Shanghai Municipality (Grant number: 21170711200 ) and General Motors collaborative research project ( GAC3599 ). Yi Liu would like to acknowledge Mr.…
View article: Adaptive time scaling for accelerating explicit finite element analysis
Adaptive time scaling for accelerating explicit finite element analysis Open
A method for accelerating an explicit finite element analysis (FEA) simulation of a modeled system or process includes performing an initial iteration of the FEA simulation according to a baseline time interval via an FEA computing network…
View article: Actively controlled vibration welding system and method
Actively controlled vibration welding system and method Open
A vibration welding system includes a controller, welding horn, an active material element, and anvil assembly. The assembly may include an anvil body connected to a back plate and support member. The element, e.g., a piezoelectric stack o…
View article: Automatic monitoring of the alignment and wear of vibration welding equipment
Automatic monitoring of the alignment and wear of vibration welding equipment Open
A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host machine, a check station, and a welding robot. At least one displacement sensor is positioned with respect to one of the welding equipm…
View article: Passively damped vibration welding system and method
Passively damped vibration welding system and method Open
A vibration welding system includes a controller, welding horn, an anvil, and a passive damping mechanism (PDM). The controller generates an input signal having a calibrated frequency. The horn vibrates in a desirable first direction at th…
View article: Clamp force and alignment checking device
Clamp force and alignment checking device Open
A check fixture measures a total clamp force applied by a welder device. The welder device includes a welding horn having a plurality of weld pads and welding anvil having a plurality of weld pads. The check fixture includes a base member …
View article: Optimization of GMAW Process Variables to Minimize Thermal Distortion
Optimization of GMAW Process Variables to Minimize Thermal Distortion Open
The optimization variables include process variables such as the number of welding segments, sequence, speed, and direction, and heat input variables such as voltage and current. Parallel computing was used to reduce the time required by t…
View article: Prediction of Aluminum to Steel RSW Joint Failure (CRADA 405)
Prediction of Aluminum to Steel RSW Joint Failure (CRADA 405) Open
General Motors, LLC has developed a resistance spot welding process to join aluminum sheet to steel for body-in-white manufacturing. Efforts to develop the process for any one joint configuration (combination of alloy and thicknesses) is i…
View article: Large-Scale Welding Process Simulation by GPU Parallelized Computing
Large-Scale Welding Process Simulation by GPU Parallelized Computing Open
The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small co…
View article: Investigation of Interfacial Layer for Ultrasonic Spot Welded Aluminum to Copper Joints
Investigation of Interfacial Layer for Ultrasonic Spot Welded Aluminum to Copper Joints Open
The bonding formation for ultrasonic welding of dissimilar metals has been shrouded in mystery because of the complex thermomechanical behavior at the bonding interface. We investigated the microstructure and phases at the bonding interfac…
View article: Simulating Microstructure Evolution of Ultrasonic Welding of Battery Tabs
Simulating Microstructure Evolution of Ultrasonic Welding of Battery Tabs Open
Ultrasonic welding offers ability to weld thin layers of malleable metals at low temperature and low power consumption. During ultrasonic welding, intensive material interactions occur due to the severe plastic deformation (SPD) and fricti…