Dissimilar metal joining by ultrasonic welding

Abstract

The dissimilar metal welding is always challenging. The different alloys have different physical and mechanical properties. In the case of the electronic component of the car, it needs to establish a joint between dissimilar metals. The useful metals for this application are copper and aluminum. Even that has good conductivity, corrosion resistance, and formability. By fusion welding technologies, these thin metal workpiece joints are not a simple technology. Using a solid-state welding technology can be a suitable solution to establish a cohesion joint in case of this task. It is well known that many suitable technologies exist, even though all of them have advantages and disadvantages. The choice of solid-state technology is the ultrasonic welding process. In the case of this process, we use pressure and high-frequency vibration for welding. Besides this process, the friction- and vibration-generated heat is lower than the metal melting temperature. The base of this technology is the ultrasound-assisted high-level formability. The optimization of these dissimilar joining technology parameters needs many prewelding and testing processes. In this work, we wanted to introduce this empirical optimization process.