Ultrasonic Welding of Aluminum to Steel: A Review

As a solid-state bonding technology, ultrasonic welding (USW) has the characteristics of green energy saving and environmental friendliness. It is more suitable for joining dissimilar metals than other technologies. The aluminum-to-steel USWed joint been widely used in automotive aviation industries. Currently, there no review literature report on USW. main physical phenomena USW process include interface temperature increase, softening, plastic deformation, formation growth IMCs, dynamic recrystallization. Hence, microstructures mechanical properties aluminum-alloy-to-low-carbon-steel, aluminum-alloy-to-stainless steel, aluminum-alloy-to-galvanized-steel-joints by are reviewed. Moreover, effect temperature, macrostructure microstructure explored. Lastly, tensile-shear fatigue strength joints numerical simulation also discussed. In addition, some new application types introduced. Finally, future trends with guidance provided.