Abstract
Abstract Al 6022 and Al 7075 aluminum alloy sheets were joined via ultrasonic spot welding (USW). Due to mechanical and thermal cycles during USW, both diffusion and mechanical mixing facilitated the formation of welded interfaces. Grain refinement occurred in the top sheet due to high temperature severe plastic deformation and resultant dynamic recrystallization, while in the bottom sheet, grain coarsening was observed due to significant heat input. The alloying element, Zn, in Al 7075 diffused into Al 6022 during USW, and diffusion behavior varied with selection of top sheet. The fracture mechanism during lap shear testing, i.e. debonding or pullout fracture, varied based on welding power, time, and selection of top sheet. Stress concentration during lap shear testing of spot welded samples was simulated using finite element analysis.
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