Molecular dynamics simulation of ultrasonic metal welding of aluminum alloys

Abstract

In this study, molecular dynamics simulation of the ultrasonic welding of aluminum alloys is presented. Ultrasonic metal welding is counted as a solid state consolidation of the mating parts, in which the growing interface temperature is far below the melting point of the material and the energy consumption is relatively low compared to the common welding processes such as arc welding. The reciprocating motion of the sonotrode on the mating parts combined with the application of external pressure in the process of ultrasonic welding is the source of temperature rise and strong plastic deformations at the mating interface. This contribution is devoted to study the interactive effect of the process parameters on the interface temperature, deformation process of the mating parts and the diffusion behavior of the interface atoms.