Abstract
A three dimensional coupled thermo-mechanical finite element model was established to simulate the process of ultrasonic spot welding of Cu to Al plates. Heat generation from both friction work of contact surfaces and material plastic deformation was considered in detail. The model did not only incorporate the material thermal softening effect but also acoustic softening effect, which can be deduced from experimental phenomena. The significant influence of acoustic softening effect was demonstrated by two comparison models (considering or not). Obtained results, including structural deformation and heat generation were compared between the two models.
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