Microstructural Evolution in Dissimilar Joint of Al Alloy and Cu during Ultrasonic Welding

Abstract

Dissimilar joints between 1050 Al alloy and Cu were prepared by ultrasonic spot welding technique to understand the joint characteristics. The joint strength was evaluated by tensile shear strength test. The joint strength increased with increasing joining energy and the joint produced with sufficiently high energy was fractured at the base metal region of Al alloy. The interface microstructure in Al alloy consists of severely deformed region due to ultrasonic vibration. In addition, the fine and equiaxed grains were observed near the joint interface in the specimens fractured at the base metal. These characteristics were significantly different from the microstructure in the bulk region of Al alloy. In contrast, the microstructure in Cu was hardly changed around the interface after ultrasonic welding. Additionally, thin intermetallic compound layer with the thickness of 40 nm was found to be formed at the joint interface in the specimens fractured at the base metal. Peak temperature during ultrasonic welding was found to be approximately 480 K at the interface, which was measured using embedded thermocouple.