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Cited by 35Advanced Welding Techniques AnalysisWelding Techniques and Residual StressesUltrasonics and Acoustic Wave Propagation

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Advances in ultrasonic welding of lightweight alloys: A review

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Abbas, Zeshan, Zhao, Lun, Deng, Jianxiong, Wang, Shicheng, Hong, Wanlu·2023·High Temperature Materials and Processes
DOI 10.1515/htmp-2022-0298
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Abstract

The lightweight alloy sheet materials have been widely used in industries such as automobiles, aviation, and aerospace. However, there are huge challenges in the structural joining process. Likewise, industries are probing new technologies and are rapidly adapting to more complex light alloy materials. The ultrasonic metal welding is a reliable solid-phase joining technology, which has incomparable development prospects in the high-strength joining of lightweight alloy sheet materials. This article summarizes the research progress of ultrasonic welding of aluminum alloy, magnesium alloy, and titanium alloy thin plates in recent years. The key features of this review article are the ultrasonic welding process, advantages, applications, and limitations. It introduces the welding process parameters to explore the breakthroughs for straightforward direction. Furthermore, to strengthen the phenomena, the current state of the ultrasonic welding of lightweight alloys and their future perspectives are also reflected.

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  • Coated surfaces can reduce the effect of IMC formation, reduce the effect of corrosion, and prevent direct contact of dissimilar metals.

    “Coated surfaces can reduce effect of IMC formation, reduce effect of corrosion and prevent direct contact of dissimilar metals3,4.”

    From Investigation of joint formation in aluminum wire and nickel-coated copper terminals using ultrasonic welding (2025) · cites this paper as [3]

    Section 3.2 discusses Zn foil changing which intermetallic compounds form in Al–Mg joints, but it does not describe a coated surface reducing IMC formation. Searches for coating and corrosion found no passage stating that coatings reduce corrosion or prevent direct contact between dissimilar metals. The References list a study using an Al coating, but give no findings supporting these effects. (LLM, conf=0.74)

    Experimental — accuracy not yet measured

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Metadata

Authors
Abbas, Z., Zhao, L., Deng, J., Wang, S., & Hong, W.
Affiliations
Shenzhen Polytechnic University (CN)
Corresponding author
Zhao, Lun
ORCID
Venue
High Temperature Materials and Processes
Publisher
Walter de Gruyter GmbH
Published
2023-01-01
Volume
42
Issue
1
ISSN
  • 0334-6455 (ISSN-L)
  • 2191-0324
DOI
10.1515/htmp-2022-0298
OpenAlex
W4388969860
Cited by
35
References
0
Citations by year
2026: 10 · 2025: 17 · 2024: 8
FWCI
3.45
Type
journal article
Language
en
Open access
Licence
Locations
  • High Temperature Materials and Processes (publishedVersion, cc-by)
  • DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion, cc-by-sa)
Funders
  • Shenzhen Polytechnic
  • National Natural Science Foundation of China (12104324)
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, light alloys, aluminum alloys, magnesium alloys, titanium alloys, thin sheet joining, welding parameters

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