An experimental investigation on joining of aluminium with steel using ultrasonic metal welding

Abstract

This paper presents some preliminary results in ultrasonic joining of ferrous and non-ferrous metals, which has recently been adopted to manufacture micro-welded parts. The effects of ultrasonic welding parameters such as vibration amplitude, weld time and weld pressure were compared through tensile shear and T-peel tests with microstructural analysis. These mechanical tests revealed that the maximum weld strength was obtained at the highest vibration amplitude. The temperature generated at the weld zone is lower than the aluminium melting temperature, which is consistent with solid state welding. Microhardness tests were also carried out to show the plastic deformation. The grain deformations, phase transformation, and aluminium diffusion were also examined through SEM and EDS analysis.