Optimization of process parameters of ultrasonic welding on dissimilar metal joints

Abstract

Nowadays the automotive industry mostly prefers innovative solid-state welding technologies that would enable to welding of lightweight and high-performance materials. in this work, 3105-h18 Aluminium alloy (Al) and pure Copper (Cu) specimens with 0.5 mm thickness have been ultrasonically welded in a dissimilar (Al-Cu) manner. optimization of process parameters of ultrasonic welding has been carried out through full factorial method, three levels of variables considered for this experimental studies namely, weld pressure, amplitude, and time, also each variable interaction with welding strength has been studied. Additionally, micro-hardness and microstructure investigation in welded joints has been studied. The result shows that the weld strength greatly influenced weld amplitude at a medium and higher level of weld pressure. The interface micro-hardness of the welded joint has lower compared to the base metal.