Abstract
To enhance the mechanical strength of an ultrasonic spot-welded Al/Al joint, an Al 2219 particle interlayer was placed between the two Al sheets during the ultrasonic spot welding process. The effects of the interlayer thickness on the microstructure and mechanical performances of the joints were systematically investigated. The results showed that, the optimum thickness of the Al 2219 particle interlayer was 10 μm, which was beneficial to enhance the weld interface temperature up to 402 °C. The bonding interface of Al/Al 2219 with a wave-like shape was sound, and no significant diffusion layer occurred. The peak lap shear tensile strength (~84.8 MPa) was obtained, which was 36% higher than that (~67.3 MPa) for the joint without the Al 2219 particle interlayer. The strengthening mechanism is caused by the increase of plastic deformation and contact areas in the weld interface.
Highlights
Al/Al joints have been widely used in the fields of power device module packing, automobile electronic technologies, and solar power controlling
Some micro/nano pits appear on the surface of the Al 2219 particle, resulting in the improvement of the friction coefficient at the weld interface
The specimen fabricated without an interlayer (Figure 5a) possessed some gaps in the weld interface where bonding was not obtained
Summary
Al/Al joints have been widely used in the fields of power device module packing, automobile electronic technologies, and solar power controlling. Bakavos et al [1] reported that Al alloys possess high conductivity, resulting in challenges when joining similar or dissimilar materials. Confirmed that the conventional fusion welding process led to weld defects, such as hot cracking, high levels of welding deformation, and poor weldability. A laser welding technique has been successfully applied to joining Al alloys [3,4]. Barnes et al [5] showed that bonding and riveting increases the costs of surface preparation and adds consumption products, respectively. Peng et al [6]
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