Microstructure investigation and optimization of process parameters of ultrasonic welding for Al - Cu dissimilar joints using design of experiment

Ultrasonic Metal Welding (UMW) employs high-power ultrasonic vibrations to join thin metal sheets of different materials, effectively addressing the thermal damage issues associated with traditional welding methods. This study aimed to optimize the joining of thin aluminum (Al) and pure copper (Cu) metal sheets using high-power ultrasonic vibration. The investigation focused on the effect of input parameters, including time, static pressure, and welding power, on the output parameter of joint strength. The results indicated that the welding time had the most significant effect on the load obtained from the Tensile-shear test. The optimal condition was determined to be a welding time of 0.98 s, a pressure of 2 bar, and a power of 85%, resulting in a maximum predicted tensile-shear test load of 753.3 N, with an error value of 11.4% obtained from the software. Microscopic images reveal that the welding mechanism in ultrasonic welding involves continuous plastic deformation, dispersion of oxide layers, and the formation and extension of micro-bonds along the weld line.