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Cited by 76Advanced Welding Techniques AnalysisMicrostructure and mechanical propertiesWelding Techniques and Residual Stresses

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Dynamic Weld evolution during ultrasonic welding of Cu–Al joints

Ma, Qiuchen, Song, Cheng, Zhou, Jianli, Zhang, Lin, Ji, Hongjun·2021·Materials Science and Engineering: A
DOI 10.1016/j.msea.2021.141724
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Abstract

Abstract Although ultrasonic welding of dissimilar metals has been widely applied in the automotive and electronic industries, the dynamic weld evolution, including deformation, breakage, and attachment, is still in a conjecture stage because of the short welding time, thin reaction layer and complex thermomechanical behavior. In this study, dissimilar welds of aluminum (Al) alloy 1060 to T2 copper (Cu) were comprehensively investigated via microstructural characterization, molecular dynamics simulations, and mechanical tests. It was found that micro-welds first formed at high asperities. Subsequently, the continuous relative friction at the interface induced severe plastic deformation on the Al side, resulting in the alternating fracture and formation of micro-welds, flattening of asperities, and attachment of Al on the Cu surface. The lap shear failure loads for the joints gradually increased with increasing welding time. The failure loads reached the maximum values of 0.9 ± 0.03 kN after a welding time of 0.29 s. Furthermore, the Cu asperities completely sunk into the Al matrix, presenting a macro-interlocking morphology at the interface. A swirl-like grain morphology with no deformation texture appeared simultaneously on the Al side. Analysis of the weld formation indicated that microstructural evolution of the joint, including material flow, grain morphology, and grain orientation, was mainly concentrated on the softer material side, providing a new understanding of the ultrasonic welding of dissimilar metals.

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Cited by

Metadata

Authors
Ma, Q., Song, C., Zhou, J., Zhang, L., & Ji, H.
Affiliations
Harbin Institute of Technology (CN)
Corresponding author
Ji, Hongjun
ORCID
Venue
Materials Science and Engineering: A
Publisher
Elsevier BV
Published
2021-08
Volume
823
Pages
141724
ISSN
0921-5093 (ISSN-L)
DOI
10.1016/j.msea.2021.141724
OpenAlex
W3180885177
Cited by
76
References
0
Citations by year
2026: 12 · 2025: 16 · 2024: 24 · 2023: 11 · 2022: 13
FWCI
5.13
Type
journal article
Language
en
Open access
closed
Licence
Locations
Materials Science and Engineering A (publishedVersion)
Funders
  • National Natural Science Foundation of China (51775140)
  • Science, Technology and Innovation Commission of Shenzhen Municipality (20200821172456002)
  • National Major Science and Technology Projects of China
  • Special Project for Research and Development in Key areas of Guangdong Province
Topics
  • Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
  • Physical Sciences › Materials Science › Metals and Alloys › Microstructure and mechanical properties
  • Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
Keywords
ultrasonic welding, dissimilar metal joining, T2 copper, weld formation mechanism, asperity deformation, material flow, grain morphology, grain orientation, lap shear strength, molecular dynamics simulation

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