Abstract
The high-strength lightweight Al-Zn-Mg-Cu alloy sheets were welded using ultrasonic spot welding with soft specification. The peak tensile shear failure load reached 7.3 kN, which satisfies the requirements of AWS D17.2 for spot-welded specimens. This is due to the fact that the material undergoes sufficient plastic deformation during the welding process with soft specification, thereby improving metallurgical bonding. Moreover, the dynamic recrystallization resulting from plastic deformation makes the grain size of the interface significantly refined. The grains with a size of 10 μm in the base metal are transformed into recrystallized grains with a size of 2 μm at most, which is in favor of improving the mechanical properties of the joint. Finally, even under soft specification conditions, excessive welding time can lead to macroscopic damage to the joint, initiation of cracks, and destruction of the grain boundary structure.
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