Open Competition 2 - Chemistry and Materials

Ultrasonic Metal Welding - Enabling the All Aluminum Vehicle

Sponsor: Ford Motor Company

• Project Performance Period: 7/1/2003 - 9/30/2007
• Total project (est.): $8,910,000.00
• Requested ATP funds: $4,395,000.00

High-volume manufacturing of aluminum automobiles requires a low-cost metal-joining technology in order to be viable. Ultrasonic metal welding overcomes weaknesses inherent in available joining methods for aluminum automotive body structures and is cost efficient and environmentally friendly. Four organizations forming a joint venture will develop a novel ultrasonic metal welding technology to meet the requirements of mass production in automotive applications. The process applies localized ultrasonic vibrations to metal components clamped under moderate pressure. This robust, solid-state welding process can join a wide variety of dissimilar alloys, thin-to-thin sections and thin-to-thick sections. Also, most oxides and surface oils do not inhibit joint weldability. However, ultrasonic metal welding has not been applied to structural welding of automobile bodies. Technical challenges include overcoming tool adhesion to the workpiece, extending tool life, and designing new ceramic piezoelectric materials for high-power transducers needed for joining thick sections. Weld performance and associated operating costs must prove comparable to that achieved in conventional steel-body construction. Ford Motor Company will head the project and intends to implement the technology in vehicle production. American Technology, Inc., and Sonobond Ultrasonics, Inc., bring expertise in ultrasonic welding equipment, and Edison Welding Institute contributes specialized knowledge in materials-joining technology. Additionally, three subcontractors will be engaged: The Ohio State University (Columbus, OH) will assist with transducer characterization, welding system design, and sensor device development and testing; The University of Michigan (Ann Arbor, MI) will develop fracture models; and Wayne State University (Detroit, MI) will perform numerical simulation and model validation. ATP support enables the assembly of this diverse, multidisciplinary research team to meet the joining challenges facing the high-volume manufacture of aluminum vehicles. The need for ATP funding stems in part from current fiscal pressures on the automotive industry, which severely limit the pursuit of high-risk research programs. In addition, the partners, other than Ford, are essentially small businesses and can allocate only modest investment capital to risky research and development projects. For this joint project to proceed, ATP funds are required. Because reducing vehicle weight is key to achieving improved fuel economy and lower emission levels, all-aluminum vehicles would provide tremendous economic and environmental benefits to the nation. Furthermore, ultrasonic metal welding would likely find application wherever weight reduction is a key objective, such as in tractor trailers, aircraft, aerospace vehicles, ship superstructures, and amphibious military vehicles.

For project information:

Kay Milewski, (313) 248-8196
kmilewsk@ford.com

Active Project Participants

• Branson Ultrasonics Corporation (formerly American Technology, Inc.) (Danbury, CT)
  [Original, Active Member]
  
• Edison Welding Institute (EWI) (Columbus, OH)
  [Original, Active Member]
  
• Sonobond Ultrasonics, Inc. (West Chester, PA)
  [Original, Active Member]
  

ATP Project Manager

H. Felix Wu, (301) 975-4685
felix.wu@nist.gov