Ultrasonic Metal Welding of Aluminum to Copper

Ultrasonic welding of aluminum to copper is widely used to join the tabs of lithium-ion batteries. In this study, ultrasonic welding was used to weld aluminum and copper sheets with a thickness of ۰.۳ mm after annealing for ۳۰ minutes at ۲۹۰ °C for aluminum and ۴۵۰ °C for copper. Ultrasonic welding was conducted at a pressure of ۵ bar and welding times of ۰.۲۵, ۰.۵, and ۰.۷۵ seconds. Then, microscopic images were prepared for metallographic analysis. Results revealed that with increasing welding time, the copper flow under horn teeth completed and due to generation of more heat, the unbonded areas at the joint interface reached to minimum at ۰.۷۵ s. With increasing time, the weld density increased from ۵۰% to ۹۰% and the effective weld thickness decreased from ۰.۱۸۵ mm to ۰.۱۷ mm. The increase in plastic deformation and temperature at the interface is the reason for these changes.

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Dissimilar ultrasonic welding ، Aluminum ، Copper