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Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs
Abstract
Ultrasonic welding is a solid-state bond created using ultrasonic energy. It has been used in the semiconductor industry for several decades, and more recently, in the automotive industry such as for lithium-ion battery welding. Although there existed numerical simulations for ultrasonic welding, the models were limited to two-layer and like materials stackups. In this study, finite element theories are introduced and simulation procedure is established for multiple sheets and dissimilar metal ultrasonic welding. The procedures require both abaqus/Standard and abaqus/Explicit to simulate the coupled mechanical-thermal phenomena over the entire weld duration with moderate computational cost. The procedure is verified and used to simulate selected specific cases involving multiple sheets and dissimilar materials, i.e., copper and aluminum. The simulation procedure demonstrates its capability to predict welding energy, distortion, and temperature distribution of the workpieces. Case studies of ultrasonic welding simulations for multiple layers of lithium-ion battery tabs are presented. The prediction leads to several innovative ultrasonic welding process designs for improved welding quality.
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Resistance soldering of the copper/aluminum joint has poor performance due to its resistance and conductivity.
“However, resistance soldering of the copper/aluminum joint has poor performance due to its resistance and conductivity7.”
From Investigation of joint formation in aluminum wire and nickel-coated copper terminals using ultrasonic welding (2025) · cites this paper as [7]
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Research works printed but not linked: 29
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Cited by
Sorted by citations
Zhang, H., Zhao, L., Abbas, Z., & Hong, W. (2025) · Scientific Reports · doi:10.1038/s41598-025-08477-2 · Cited by 7
Metadata
- Authors
- Lee, D., Kannatey-Asibu, E., & Cai, W.
- Affiliations
- e-mail:
- e-mail: Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48105
- General Motors (United States) (US)
- ORCID
- Cai, Wayne
- Venue
- Journal of Manufacturing Science and Engineering
- Publisher
- ASME International
- Published
- 2013-11-18
- Volume
- 135
- Issue
- 6
- ISSN
- 1087-1357 (ISSN-L)
- 1528-8935
- OpenAlex
- W2092420869
- Cited by
- 61
- References
- 0
- Citations by year
- 2026: 3 · 2025: 5 · 2023: 8 · 2022: 6 · 2021: 3 · 2020: 5 · 2019: 5 · 2018: 8 · 2017: 1 · 2016: 8 · 2015: 4 · 2014: 3 · 2013: 2
- FWCI
- 7.51
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- Journal of Manufacturing Science and Engineering (publishedVersion)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
- Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
- Physical Sciences › Engineering › Mechanics of Materials › Ultrasonics and Acoustic Wave Propagation
- Keywords
- ultrasonic welding, multiple layers, dissimilar metal welding, solid-state bonding, welding distortion, temperature distribution, finite element analysis
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