Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding

The demand for joining dissimilar metals has exponentially increased due to the global concerns about climate change, especially electric vehicles in automotive industry. Ultrasonic welding (USW) surges as a very promising technique join metals, providing strength and conductivity, addition avoid metallurgical defects, such formation of intermetallic compounds, brittle phases porosities. However, USW is sensitive process, which depends on many parameters. This work evaluates impact process parameters quality ultrasonic spot welds between copper aluminium plates. weld assessed based tensile joints metallographic examination cross-sections. Furthermore, energy examined different conditions. done evaluate influence each parameter heat input resulting from friction at interface quality. From obtained results, it was possible optimise achieve satisfactory 1.0 mm thick Al–Cu plate terms mechanical properties.