Interfacial Reaction Research Articles

Crystallographic anisotropy-dependent mechanochemical removal of GaAs: Nanoasperity experiments and atomistic simulations

In this paper, the nanoasperity wear tests on GaAs surfaces with different crystallographic orientations against SiO2 microsphere were performed using AFM. The removal behavior characterized by in-situ AFM imaging significantly relies on crystallographic anisotropy (111 > 110 > 100). The atomic structure of worn area characterized by HRTEM shows perfect crystal lattice, demonstrating the dominate role of the interfacial mechanochemical reactions during the material removal of GaAs. DFT calculations were conducted and the results reveal that the charge re-distribution behavior at the SiO2/GaAs interface governs the mechanochemical reactions, essentially leading to the crystallographic anisotropy dependence. This study not only enriches the mechanochemical reaction mechanism, but also benefits for the CMP optimization for GaAs.

Molecule-Level Multiscale Design of Nonflammable Gel Polymer Electrolyte to Build Stable SEI/CEI for Lithium Metal Battery

HighlightsNonflammable gel polymer electrolyte (SGPE) is developed by in situ polymerizing trifluoroethyl methacrylate (TFMA) monomers with flame-retardant triethyl phosphate (TEP) solvents and LiTFSI–LiDFOB dual lithium salts.Molecular polarity interaction between TEP and PTFMA mitigates interfacial reactions and changes the solvation of Li+.SGPE forms stable inorganic-rich solid electrolyte interface/cathode electrolyte interface layer, exhibiting well compatibility with Li anode and LiCoO2-type high-voltage cathode.

Characterizing sliding wear behavior of A1100/AlFe (p) composites produced via repeated fold-forging and annealing

Abstract Aluminum matrix/aluminum-iron intermetallic composite materials pose challenges in plastic processing due to the susceptibility of hard intermetallic compound particles to fracture. This study introduces a novel fabrication method involving pure iron mesh, hot-dip aluminum plating, and solidification. Through ten consecutive folding, forging, and intermediate annealing cycles, aluminum matrix and iron undergo diffusion, leading to the formation of Fe2Al5 and FeAl3 interface reaction layers, as confirmed by X-ray diffraction analysis. Subsequent forging cycles cause the breakage or detachment of Fe2Al5 and FeAl3 particles from the interface, resulting in the formation of large-sized Fe2Al5 and small-sized Fe2Al5 intermetallic particles. FeAl3 intermetallic particles are observed via microscopic examination. These particles can be uniformly dispersed within the aluminum matrix through plastic flow, enabling the successful fabrication of A1100/Fe2Al5 and AlFe3 composite sheets. Furthermore, the study investigates the impact of intermetallic compound content, sliding speed, and forward load on the dry sliding wear of A1100/FeAl composites. It is found that Fe2Al5 and AlFe3 intermetallic compound particles effectively mitigate adhesive wear, plowing, and oxidative wear of the composites. With an AlFe intermetallic compound content of 4.3 wt.%, the volume wear rate remains low under conditions corresponding to PV = 56.652 (equivalent to a normal load of 19.6 kPa and a sliding speed of 2.87 m s−1).

Surface Property Regulation of a Magnetron-Sputtered NiOx Hole Transport Layer for High-Performance Inverted Perovskite Solar Cells.

The inverted perovskite solar cells (PSCs) are gaining increasing attention recently for their unprecedented advantages, such as better integration with tandem and flexible designs, negligible hysteresis, good operational stability, and compatibility with commercially scalable fabrication approaches. Nickel oxide (NiOx) films prepared by magnetron sputtering technology exhibit excellent scalability and reproducibility, which could well meet the requirements of the large-scale production of inverted PSCs. However, NiOx prepared by vacuum methods generally has fewer surface hydroxyl groups, deteriorating the wettability and damaging the interface contact with the perovskite. Particularly, the Ni3+ defects on the NiOx surface could lead to unfavorable redox reactions with organic cations in the perovskite under high temperatures, promoting the rapid degradation of the perovskite. Thus, surface regulation of sputtered NiOx is imperative for high-performance PSCs. Herein, 4-(trifluoromethyl) phenylcarbamate hydrochloride (TFFA) was used to regulate the surface properties of sputtered NiOx. The strongly electronegative F ions in TFFA passivated the Ni3+ defects on the NiOx surface, suppressed unfavorable interface reactions, and improved charge recombination. The polar ammonium functional group was used to adjust the surface energy of NiOx, thereby improving the wettability and optimizing the crystallization kinetics of the perovskite. As a result, the power conversion efficiency (PCE) of PSCs reached 22.76%, which was among the highest PCEs reported for sputtered NiOx-based inverted PSCs to date. Moreover, the unencapsulated target devices exhibited better stability, maintaining over 85% of the initial PCE after aging for approximately 1200 h in a N2 environment. Our achievements pointed out a practical strategy for enhancing the performance of sputtered NiOx-based inverted PSCs, which could potentially accelerate the development and application of large-area PSCs.

Construction of a novel Z-scheme FeTiO3/MOF-derived In2S3 catalyst for visible-light-driven photo-Fenton degradation of pollutants

The rapid recombination rate of photoexcited carriers for iron titanate (FeTiO3) is still limited the process performance of photo-Fenton. This article reports the successful synthesis of the highly efficient Z-scheme FeTiO3/MOF-derived In2S3 photocatalyst using the hydrothermal method, compensating for the susceptibility of FeTiO3 photo-generated carriers to complexation to a certain extent. A series of characterization have been carried out to explore the structure, morphology and composition of FeTiO3/MOF-derived In2S3 heterostructure. The 0.5 FeTiO3/MOF-derived In2S3 exhibits the excellent photo-Fenton performance for TCH, Cr6+ and OTC, the degradation rate constants (k2) are up to 0.6297 L·mg−1·min−1, 1.332 L·mg−1·min−1, and 0.427 L·mg−1·min−1, respectively. Active species capture experiments and electron paramagnetic resonance (EPR) spectra show that photo-generated holes (h+) and superoxide radicals (·O2-) are present in the photo-Fenton system. The superior photo-Fenton performance is mainly manifested in the following: the MOF-derived In2S3 micro-floral carrier extends the reaction interface of 0.5 FM-I; FeTiO3 effectively enhances the photo-absorption ability of 0.5 FM-I in visible range; the construction of Z-scheme FeTiO3/MOF-derived In2S3, forming the new carriers transport channels and enhancing the generation of ·O2- and ·OH. This experimental exploration provided a reasonable experimental basis for the preparation of efficient photocatalysts.

The Interfacial Reaction between Amorphous Ni-W-P Coating and Sn-58Bi Solder

With the rapid development of the advanced electronic packaging field, the requirements for the connection between solder and Cu substrate are becoming increasingly stringent. Currently, the commonly used Ni-P diffusion barrier layer in the industry lacks long-term reliability, and its resistivity is higher than that of other substrates. This paper introduces the highly conductive metal element W to modify the binary Ni-P coating and prepares a ternary Ni-W-P coating through electrodeposition to improve this situation. The key parameters for the electrodeposition of ternary Ni-W-P are determined. The isothermal aging reaction of Ni-W-P with Sn-Bi solder at 100 °C was studied, and the results showed that, compared to the conventional Ni-P coating, the Ni-W-P barrier coating with higher W content has a much longer lifespan as a barrier layer and exhibits significantly better electrical conductivity. Additionally, the reaction mechanism between Ni-W-P and the Sn-Bi solder is proposed. This research presents a promising advancement in the development of barrier layers for electronic packaging, potentially leading to more reliable and efficient electronic devices. Introducing tungsten into the Ni-P matrix not only extends the lifespan of the coating but also enhances its electrical performance, making it a valuable innovation for applications requiring high conductivity and durability. This study could guide further investigations into the application of ternary coatings in various electronic components, paving the way for improved designs and materials in the semiconductor industry.

Magnetically Separable Chiral Poly(ionic liquid) Microcapsules Prepared Using Oil-in-Oil Emulsions.

This article presents a method for producing chiral ionic liquid-based polyurea microcapsules that can be magnetically separated. The method involves entrapping hydrophilic magnetic nanoparticles within chiral polyurea microspheres. The synthetic process for creating these magnetic polyurea particles involves oil-in-oil (o/o) nano-emulsification of an ionic liquid-modified magnetite nanoparticle (MNPs-IL) and an ionic liquid-based diamine monomer, which comprises a chiral bis(mandelato)borate anion, in a nonpolar organic solvent, toluene, and contains a suitable surfactant. This is followed by an interfacial polycondensation reaction between the isocyanate monomer, polymethylenepolyphenyl isocyanate (PAPI 27), and the chiral diamine monomer, which generates chiral polyurea microcapsules containing magnetic nanoparticles within their cores. The microcapsules generated from the process are then utilized to selectively adsorb either the R or S enantiomer of tryptophan (Trp) from a racemic mixture that is dissolved in water, in order to evaluate their chiral recognition capabilities. During the experiments, the magnetically separable chiral poly(ionic liquid) microcapsules, which incorporated either the R or S isomer of chiral bis(mandelato)borate, exhibited exceptional enantioselective adsorption performance. Thus, the chiral polymeric microcapsules embedded with the R-isomer of the bis(mandelato)borate anion demonstrated significant selectivity for adsorbing L-Trp, yielding a mixture with 70% enantiomeric excess after 96 h. In contrast, microcapsules containing the S-isomer of the bis(mandelato)borate anion preferentially adsorbed D-Trp, achieving an enantiomeric excess of 73% after 48 h.

Engineering the conductive network of missing-linker metal-organic framework for improved performance in aqueous zinc-ion batteries

Aqueous zinc-ion batteries (ZIBs) face critical challenges such as interfacial side reactions, corrosion, and passivation of the zinc anode. In this work, we introduce a novel zinc anode featuring a 3D ordered macroporous (3DOM) architecture based on a missing-linker ZIF-8 framework (Zn@Fc-ZIF-8). This innovative design achieves remarkable stability, maintaining performance for over 4000 h at a current density of 0.25 mA cm−2 in a symmetric cell-over 30 times longer than a bare Zn anode. Additionally, by integrating carbon nanotubes (CNTs) within the 3DOM Fc-ZIF-8 skeleton to create a highly conductive network (3DOM Fc-ZIF-8/CNTs), we extend the anode's lifetime to 1500 h at a high current density of 5 mA cm−2. The strategic regulation of the ZIF-8 structure using ferrocene formic acid (Fc) and the incorporation of CNTs result in a full cell with the bi-functional Zn@Fc-ZIF-8/CNTs anode, achieving a high specific capacity of 380.5 mAh g−1 and a coulombic efficiency (CE) of 99.8 %. These findings underscore the significant potential of MOF-based anodes in addressing dendrite formation and advancing the practical application of ZIBs.

Cerium(III)-induced structural transformation of hexagonal birnessite: Effect of mineral phase transition on arsenite transport and valence changes

The widespread mining and application of rare earth elements (REEs) have led to their continuous accumulation in the environment, with increasing concentrations in soil. The interaction between the most abundant REEs, cerium (Ce), and the prevalent hexagonal birnessite (HB) in the environment is worth attention. HB is one of the most effective metal oxides for the oxidation of arsenite [As(III)] and subsequent adsorption, and thus for arsenic (As) immobilization. Therefore, in this study, we investigated the effect of the presence of Ce(III) ion on the HB formation process and the influence of generating minerals on the oxidation and removal of As(III). Research has found that the interfacial reactions of REEs in manganese (Mn) minerals not only affect their cycling but also alter the properties of the Mn minerals, thereby affecting the environmental fate of As. The results indicated that the presence of Ce ions affected the structure of HB during mineral synthesis and reduced the crystallinity of the conversion products. Their substitution for Mn(IV) in the lattice increased the specific surface area of minerals, reduced particle size, and produced more hydroxyl groups that were conducive to the immobilization of As(III). Meanwhile, Ce(III) was oxidized to Ce(IV) during the formation of Ce-bearing hexagonal birnessite (Ce-HB), and CeO2 nanoparticles were formed on the mineral surface and the removal rate of As(III) by Ce-HB was greatly improved. When the As concentration was lower than 6 mg·L−1, the removal effect of Ce-HB could reach the drinking water standard. However, the oxidation rate decreased due to the decrease in the proportion of Mn(IV). This study fundamentally reveals the behavior of HB coexisting with Ce in the migration and transformation of As(III) in the environment.

Self-Assembled Monolayer Suppresses Interfacial Reaction between NiOx and Perovskite for Efficient and Stable Inverted Inorganic Perovskite Solar Cells.

Inorganic NiOx has attracted tremendous attention in organic-inorganic hybrid perovskite solar cells (PSCs) in recent years but is relatively less used in all-inorganic PSCs. In this study, we have discovered and confirmed the detrimental interfacial reaction between NiOx and DMAI-containing CsPbI3 inorganic perovskites. Thus, a self-assembled monolayer, Br-2PACz, is employed to modify the NiOx surface to obstruct the adverse interfacial reaction and further improve the device performance. The results demonstrate that Br-2PACz modification on NiOx can also improve interface contact, perovskite film morphology, and energy level alignments. Consequently, a champion power conversion efficiency (PCE) of 19.34% with a high open-circuit voltage (VOC) of 1.15 V is obtained for inverted NiOx/Br-2PACz-based CsPbI3 PSCs compared to the reference NiOx-based PSC with a moderate PCE of 15.16% (VOC 1.05 V). Moreover, the stabilities of both CsPbI3 films and devices exhibited significant enhancement after Br-2PACz modification. The unpacked PSCs could maintain 80, 73, and 89% of the initial efficiency after aging in 30-35% RH for 960 h, heating at 60 °C for 48 h, and continuous illumination for 284 h, respectively, highly superior to the reference devices. Our work offers a facile and effective approach for developing high-performance inverted NiOx-based CsPbI3 PSCs.

Pickering Emulsion Promoted Interfacial Sequential Chemo-Biocatalytic Reaction for the Synthesis of Chiral Alcohols from Styrene.

Chemo-biocatalytic cascades have emerged as a promising approach in the realm of advanced synthesis. However, reconciling the incompatible reaction conditions among distinct catalytic species presents a significant challenge. Herein, we introduce an innovative solution using an emulsion system stabilized by Janus silica nanoparticles, which serve as a bridge for both chemo-catalysts and biocatalysts at the interface. The chemo-catalyst is securely anchored within a hydrophobic polymer matrix, ensuring its residence in an organic environment. Meanwhile, the negatively charged E. coli cells containing enzymes are attracted to the aqueous phase at the interface, facilitating their optimal positioning. We demonstrate the efficacy of this system through a two-step cascade reaction. Initially, the oxidation of styrene to acetophenone using palladium as a chemocatalyst achieves a 6-fold increase in yield compared to the control system. Subsequently, the reduction of achiral acetophenone to its chiral alcohol derivative presents a 17-fold yield enhancement relative to that of the control reaction. Importantly, our system exhibits versatility, accommodating a wide range of substrates for both individual and sequential reactions. This work not only validates the concept but also paves the way for the integration of chemo- and biocatalysts in the synthesis of a broader array of high-value chemical compounds.

Structural Regulation Enables High Interfacial Functionality for Ni-Rich Single-Crystalline Cathodes.

Ni-rich single-crystalline layered cathodes have garnered significant attention due to their high energy density and thermal stability. However, they experience severe capacity degradation caused by lattice strain and interfacial side reactions during practical applications. In this study, an effective yttrium modification method is employed to stabilize the structure of Ni-rich single-crystalline LiNi0.83Mn0.05Co0.12O2 (SC-NMC83) to solve these issues. This innovative approach successfully immobilizes oxygen within the material, preventing crack formation while simultaneously broadening the diffusion path of Li+. The yttrium-modified sample (SC-NMC83-Y) exhibits a superior capacity retention compared to the SC-NMC83 sample, with values of 90% and 76.1% after 100 cycles, respectively. This work demonstrates the promising potential of a doping strategy for Ni-rich single-crystalline cathodes and paves a pathway for its practical implementation, such as all-solid-state batteries.

From Graphene Oxide to Graphene: Changes in Interfacial Water Structure and Reactivity Using Deep Neural Network Force Fields

From Graphene Oxide to Graphene: Changes in Interfacial Water Structure and Reactivity Using Deep Neural Network Force Fields

Fundamental Understanding of Interface Chemistry and Electrical Contact Properties of Bi and MoS2.

The interface properties and thermal stability of bismuth (Bi) contacts on molybdenum disulfide (MoS2) shed light on their behavior under various deposition conditions and temperatures. The examination involves extensive techniques including X-ray photoelectron spectroscopy, scanning tunneling microscopy (STM), and scanning tunneling spectroscopy (STS). Bi contacts formed a van der Waals interface on MoS2 regardless of deposition conditions, such as ultrahigh vacuum (UHV, 3 × 10-11 mbar) and high vacuum (HV, 4 × 10-6 mbar), while the oxidation on MoS2 has been observed. However, the semimetallic properties of Bi suppress the impact of defect states, including oxidized-MoS2 and vacancies. Notably, the n-type characteristic of Bi/MoS2 remains unaffected, and no significant changes in the local density of states near the conduction band minimum are observed despite the presence of defects detected by STM and STS. As a result, the Fermi level (EF) resides below the conduction band of MoS2. The study also examines the impact of annealing on the contact interface, revealing no interface reaction between Bi and MoS2 up to 300 °C. These findings enhance our understanding of semimetal (Bi) contacts on MoS2, with implications for improving the performance and reliability of electronic devices.

Wettability and Interfacial Reaction between the K492M Alloy and an Al2O3 Shell.

In this study, wettability behavior and the interaction between the K492M alloy and an Al2O3 shell were investigated at 1430 °C for 2~5 min. The microstructural characterization of the alloy-shell interface was carried out by optical microscopy (OM) and scanning electron microscopy (SEM). The results indicated that the interaction could cause a sand adhesion phenomenon affecting the alloy, and the attached products were Al2O3 particles. In addition, the wetting angles of the alloys located on the shell were 125.2°, 109.4°, 97.0°, and 95.0°, respectively, as the contact time was increased from 2 to 5 min. Apparently, the wettability of the alloy in relation to the shell had a relationship with the contact time, where a longer contact time was beneficial to the permeation of the alloy into the shell and the interaction between the two components. No significant chemical products could be detected in the interaction layer, indicating that only the occurrence of the physical dissolution of the shell took place in the alloy melt.

Silicon surface texturing via TBAB-SDS composite additives enhanced copper-assisted chemical etching

Uneven etching and low fabrication efficiency impede the large-scale applications of copper-assisted chemical etching (Cu-ACE) for texturing light-trapping structures on the surface of silicon wafers. To address this, a composite additive composed of tetrabutylammonium bromide (TBAB) and sodium dodecyl sulfate (SDS) was introduced into the Cu-ACE system. The results indicated that TBAB accelerated the etching rate and improved the texturing uniformity, while SDS enlarged the size of the formed structures and enhanced their ultraviolet light absorption efficiency. The prepared inverted pyramid structure reduced the reflectivity of the silicon wafer surface to 3.8 %, thus exhibiting efficient light-trapping capabilities. The etching evolution under various TBAB concentrations and different HF/H2O2 ratios was studied by characterizing the surface contact angle and copper deposition morphology. The results indicated that electrostatic attraction between TBAB and dangling bonds on the silicon wafer surface enhanced material transfer at the reaction interface and changed the electron distribution around dangling bonds, thus facilitating the catalytic metal attack on these bonds. The copper ion reactivity was decreased due to complexation between the dissociated alkyl sulfate ions of SDS and copper ions, which favored the deposition of larger copper nanoparticles during etching, thereby increasing the size of structures. This research offers valuable insights to enable the large-scale applications of Cu-ACE.

Electrolyte Additive l-Lysine Stabilizes the Zinc Electrode in Aqueous Zinc Batteries for Long Cycling Performance.

Rechargeable aqueous Zn-ion batteries (AZIBs) have been recognized as competitive devices for large-scale energy storage due to their characteristics of low cost, safe operation, and environmental friendliness. Nevertheless, their practical applications are greatly limited by zinc dendrite growth and side reactions occurring at the anode/electrolyte interface. Herein, we propose an effective and simple electrolyte engineering strategy, which is the introduction of l-lysine additive containing two amino groups and one carboxyl group into a ZnSO4 electrolyte to achieve stable and reversible Zn depositions. Theoretical calculations and experimental results reveal that the l-lysine can adsorb on the Zn anode surface due to the strong coordination effects between amino groups and Zn metal (Zn-N binding) and induce the reduction of ZnSO4 into inorganic ZnS, which can not only prevent interfacial side reactions but also regulate interfacial electric field on the zinc electrode surface to guide uniform Zn2+ electrodeposition to inhibit zinc dendrites. Consequently, the l-lysine additive in the electrolyte enables Zn||Zn symmetric cells to achieve an ultralong stable cycling up to 2400 h at 1 mA cm-2 with a low polarization of only about 16 mV and Zn||Cu asymmetric cells to obtain a high average Coulombic efficiency of 99.80% after stably cycling for more than 2000 h at 2 mA cm-2 (1 mAh cm-2). In addition, the Zn||MnO2@CNT full cell in an l-lysine-containing electrolyte also exhibits good cycling performance. This study offers a new perspective on multifunctional electrolyte additive for achieving highly reversible Zn metal anodes in AZIBs.

Effects of Li1.3Al0.3Ti1.7(PO4)3 solid-state electrolytes on the safety of hybrid solid–liquid batteries

Hybrid solid–liquid batteries (HSLBs) are emerging as promising solutions to address the safety issues of lithium-ion batteries. However, the effects of solid-state electrolytes (SSEs) on battery safety remain unclear, hindering the large-scale application of HSLBs. This paper presents a comprehensive investigation on the safety performance of HSLBs with different amounts of nano-sized Li1.3Al0.3Ti1.7(PO4)3 (LATP) SSEs in the LiNi0.9Co0.05Mn0.05O2 cathode under thermal, electrical, and mechanical abuse conditions. The HSLBs with LATP SSEs exhibit significantly enhanced tolerance to overcharge, as the battery with 5 wt% LATP does not go into thermal runaway throughout the whole overcharge process. In-depth characterizations reveal that the LATP additives experience electrochemical delithiation during overcharge and generate a protective coating layer on the cathode surface, thus effectively mitigating the cathode structural changes and cathode-electrolyte interfacial reactions. Benefiting from the coating layer, the HSLBs with LATP SSEs also exhibit reduced temperature rise rate and retarded thermal runaway during the accelerating rate calorimetry and oven tests, as well as enhanced rate performance and cycling stability. Finally, the safety, electrochemical performance, and cost of HSLBs and conventional LIBs are comprehensively compared through a radar graph, aiming to provide guidance for the rational design of high–energy density and high-safety batteries.

First‐Principles Molecular Dynamics Study on Reductive Stability of High Concentration Electrolyte on Zn doped Cu Current Collector Surface

In enhancing the lifespan of anode‐free Li metal batteries (AFLMBs), the current collector (CC) engineering is crucial for achieving uniform and dendrite‐free lithium deposition. The commonly used copper (Cu) CC is unsatisfactory because of its poor lithiophilicity. Here, we consider Zn doping on the Cu CC surface (Zn‐Cu) and explore the reductive stability of a high‐concentration electrolyte (HCE) consisting of 3.6 M LiPF6 salt in a mixture of EC and DEC on the Zn‐Cu (111) surface (HCE|Zn‐Cu) using DFT and AIMD simulations. The interfacial reactions on the HCE|Zn‐Cu system are compared to those on the pristine Cu (111) surface. We have also studied the effect of electron‐rich environments on the decomposition mechanism of the HCE mixture on both the CC surfaces. It is found that the HCE mixture is electrochemically stable on both Cu and Zn‐Cu surfaces in a neutral environment. However, under electron‐rich conditions, only one DEC molecule has decomposed upon contact with the Cu CC surface, while the two PF6‐ anion groups from Li salts have decomposed much faster when the HCE mixture interacts with the Zn‐Cu surface. Our results indicate that Zn doping suppresses undesirable solvent decomposition and improves quality of the solid electrolyte interphase (SEI) layer.

Effect of an Ultrasonic Vibration on the Microstructure and Properties of Al Alloy/Steel Laser Welding-Brazing Joints

This study analyzes the influence of different ultrasonic amplitudes on the microstructure composition, microhardness, tensile strength, and corrosion resistance of Al alloy/steel laser welding-brazing joints assisted by ultrasonic vibration. The application of ultrasonic vibration did not change the microstructure composition of the joints but refined them. The joints were all composed of θ-Fe(Al, Si)3 and τ5-Al7.2Fe1.8Si formed at the interface reaction zone, as well as an α-Al solid solution and Al-Si eutectic phase generated in the weld seam zone. Meanwhile, the thickness of the IMCs at the interface decreased with an increase in the ultrasonic amplitude. When the ultrasonic amplitude was 8 μm, the IMCs thickness was a minimum of 1.62 μm. In this condition, the reduction of the IMCs thickness and the refined grain of joints made the microhardness and tensile strength reach the maximum. The fracture of joints with ultrasonic amplitudes of 0 and 4.8 μm began at the weld seam and extended to the interface reaction zone at the steel side, while the fracture of joints was located in the heat-affected zone (HAZ) of the Al alloy side when the ultrasonic amplitude was 8.0 and 11.2 μm. The fracture mode of the former presented a typical mixed fracture with cleavage steps and tearing edges, and that of the latter showed ductile fracture with uniform and fine ductile dimples. The corrosion resistance of the joints was improved by adding ultrasonic vibration. When the ultrasonic amplitude was 8 μm, its corrosion resistance was optimum; it was ascribed to a dense oxide film formed on the surface of the metal under the action of ultrasonic vibration.