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Science and Technology of Welding and Joining Volume 16, 2011 - Issue 2
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Original Article

Ultrasonic metal welding of AA 6022‐T4 lap joints: Part I – Technological characterisation and static mechanical behaviour

M AnnoniDipartimento di Meccanica, Politecnico di Milano, Via La Masa 1, MilanoI‐20156, ItalyCorrespondence[email protected]
&
M CarboniDipartimento di Meccanica, Politecnico di Milano, Via La Masa 1, MilanoI‐20156, Italy
Pages 107-115 | Received 28 Sep 2010, Accepted 02 Nov 2010, Published online: 12 Nov 2013

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Danka Labus Zlatanovic, Jean Pierre Bergmann, Sebastian Balos, Jörg Hildebrand, Mirjana Bojanic-Sejat & Saurav Goel. (2023) Effect of surface oxide layers in solid-state welding of aluminium alloys – review. Science and Technology of Welding and Joining 28:5, pages 331-351.
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Muhammad Bilal Shahid, Seung-Chang Han, Tea-Sung Jun & Dong-Sam Park. (2019) Effect of process parameters on the joint strength in ultrasonic welding of Cu and Ni foils. Materials and Manufacturing Processes 34:11, pages 1217-1224.
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Shoichi Nambu, Kengo Seto, Jhe-Yu Lin & Toshihiko Koseki. (2018) Development of a bonding interface between steel/steel and steel/Ni by ultrasonic welding. Science and Technology of Welding and Joining 23:8, pages 687-692.
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M. Feng, Y. Li, C. Zhao & Z. Luo. (2016) Mechanical properties and interface morphology of Mg/Al ultrasonic spot weld bonding welds. Science and Technology of Welding and Joining 21:8, pages 688-699.
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H. K. Ma, D. Q. He & J. S. Liu. (2015) Ultrasonically assisted friction stir welding of aluminium alloy 6061. Science and Technology of Welding and Joining 20:3, pages 216-221.
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M Carboni & M Annoni. (2011) Ultrasonic metal welding of AA 6022‐T4 lap joints: Part II – Fatigue behaviour, failure analysis and modelling. Science and Technology of Welding and Joining 16:2, pages 116-125.
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Articles from other publishers (47)

Junqi Li & Frank Balle. (2023) In-situ observation of the bond formation process during ultrasonic metal welding of Al/Cu joints using Laser Doppler Vibrometry. Journal of Manufacturing Processes 106, pages 1-11.
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Shun Tokita, Cheng Yi Liu & Yutaka S. Sato. (2023) Effects of material combination for ultrasonic spot welding on microstructure and strength of Al/Al, Al/Cu, and Al/Ni dissimilar joints. Journal of Materials Research and Technology 26, pages 7619-7633.
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Elie Abi Raad & Michael Vorländer. (2023) Acoustic monitoring of weld strength in ultrasonic metal welding by tracking welding stages. Journal of Manufacturing Processes 101, pages 1055-1064.
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Ated Ben Khalifa, Sonia Braiek, Anis fradj & Moez Trigui. (2022) Experimental investigation of joints strength obtained by ultrasonic welding and soldering under pure T-peel tests using DIC. Welding in the World 67:2, pages 495-511.
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Koen Faes, Rafael Nunes, Sylvia De Meester, Wim De Waele, Felice Rubino & Pierpaolo Carlone. (2023) Influence of the Process Parameters on the Properties of Cu-Cu Ultrasonic Welds. Journal of Manufacturing and Materials Processing 7:1, pages 19.
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X.M. Cheng, K. Yang, J. Wang, W.T. Xiao & S.S. Huang. (2022) Ultrasonic system and ultrasonic metal welding performance: A status review. Journal of Manufacturing Processes 84, pages 1196-1216.
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Rafael Nunes, Koen Faes, Sylvia De Meester, Wim De Waele & Andrzej Kubit. (2022) Influence of welding parameters and surface preparation on thin copper–copper sheets welded by ultrasonic welding process. The International Journal of Advanced Manufacturing Technology 123:1-2, pages 373-388.
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Michael de Leon & Hyung-Seop Shin. (2022) Review of the advancements in aluminum and copper ultrasonic welding in electric vehicles and superconductor applications. Journal of Materials Processing Technology 307, pages 117691.
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Cailing Wang, Yanfeng Xing, Jingyao Hu, Junding Luo & Sheng Zeng. (2022) Investigation on mechanism of ultrasonic welding AZ31B/5052 joint with laser texturing on mental surface. The International Journal of Advanced Manufacturing Technology 122:1, pages 159-171.
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Bharat Sanga, Reeta Wattal & D.S. Nagesh. (2022) Weld joint characterization in ultrasonic welding of phosphor bronze sheets. Engineering Science and Technology, an International Journal 30, pages 101040.
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Fuxing Ye, Yonghui Wang, Hewan Lu & Yongming Guo. (2022) Study on the bonding mechanism of multilayer copper with nickel sheet in ultrasonic welding process. Materials Research Express 9:2, pages 026527.
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Aytekin Ulutaş. 2022. Handbook of Research on Advancements in the Processing, Characterization, and Application of Lightweight Materials. Handbook of Research on Advancements in the Processing, Characterization, and Application of Lightweight Materials 121 152 .
Rafael Gomes Nunes Silva, Sylvia De Meester, Koen Faes & Wim De Waele. (2022) Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding. Journal of Manufacturing and Materials Processing 6:1, pages 6.
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Vijay Dodiya, Sarthak Bhavsar, Naman Kansara, Nikhil Murarka, Keyur P. Desai, Harshit K. Dave & Himanshu V. Patel. 2021. Advances in Manufacturing Systems. Advances in Manufacturing Systems 319 327 .
Sagil James & Christopher Dang. (2020) Investigation of shear failure load in ultrasonic additive manufacturing of 3D CFRP/Ti structures. Journal of Manufacturing Processes 56, pages 1317-1321.
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Sisir Dhara & Abhishek Das. (2020) Impact of ultrasonic welding on multi-layered Al–Cu joint for electric vehicle battery applications: A layer-wise microstructural analysis. Materials Science and Engineering: A 791, pages 139795.
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H. Peng, D.L. Chen, X.F. Bai, P.Q. Wang, D.Y. Li & X.Q. Jiang. (2020) Microstructure and mechanical properties of Mg-to-Al dissimilar welded joints with an Ag interlayer using ultrasonic spot welding. Journal of Magnesium and Alloys 8:2, pages 552-563.
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H. Li & B. Cao. (2019) Effects of welding pressure on high-power ultrasonic spot welding of Cu/Al dissimilar metals. Journal of Manufacturing Processes 46, pages 194-203.
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Ghadanfer Hussein Ali & Sabah Khammass Hussein. (2019) Friction spot lap joining of the anodized aluminium alloy 6061 with high-density polyethylene sheets. World Journal of Engineering 16:4, pages 539-549.
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Shimaalsadat Mostafavi, Daniel Frank Hesser & Bernd Markert. (2019) Detection of terminal oscillation pattern in ultrasonic metal welding. Journal of Manufacturing Processes 41, pages 159-167.
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Arimoto, Sasaki, Doi & Kim. (2019) Ultrasonic Bonding of Multi-Layered Foil Using a Cylindrical Surface Tool. Metals 9:5, pages 505.
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Abhishek Das, Iain Masters & David Williams. (2018) Process robustness and strength analysis of multi-layered dissimilar joints using ultrasonic metal welding. The International Journal of Advanced Manufacturing Technology 101:1-4, pages 881-900.
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Zeng-Lei Ni & Fu-Xing Ye. (2019) Microstructure and Mechanical Properties of an Ultrasonic Spot-Welded Aluminum-to-Aluminum Joint: Response to Interlayer Thickness. Materials 12:3, pages 369.
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H. Peng, D.L. Chen, X.F. Bai, X.W. She, D.Y. Li & X.Q. Jiang. (2019) Ultrasonic spot welding of magnesium-to-aluminum alloys with a copper interlayer: Microstructural evolution and tensile properties. Journal of Manufacturing Processes 37, pages 91-100.
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Z.L. Ni & F.X. Ye. (2018) Ultrasonic spot welding of aluminum alloys: A review. Journal of Manufacturing Processes 35, pages 580-594.
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Austin A. Ward, Yibing Zhang & Zachary C. Cordero. (2018) Junction growth in ultrasonic spot welding and ultrasonic additive manufacturing. Acta Materialia 158, pages 393-406.
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Mantra Prasad Satpathy, Swayam Bikash Mishra & Susanta Kumar Sahoo. (2018) Ultrasonic spot welding of aluminum-copper dissimilar metals: A study on joint strength by experimentation and machine learning techniques. Journal of Manufacturing Processes 33, pages 96-110.
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Z.L. Ni & F.X. Ye. (2017) Ultrasonic spot welding of Al sheets by enhancing the temperature of weld interface. Materials Letters 208, pages 69-72.
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Mantra Prasad Satpathy, Abhishek Kumar & Susanta Kumar Sahoo. (2017) Effect of Brass Interlayer Sheet on Microstructure and Joint Performance of Ultrasonic Spot-Welded Copper-Steel Joints. Journal of Materials Engineering and Performance 26:7, pages 3254-3262.
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Yu Huang, Gen Li, WenJun Shao, ShiHua Gong & XiaoLong Zhang. (2016) A novel dual-channel weld seam tracking system for aircraft T-joint welds. The International Journal of Advanced Manufacturing Technology 91:1-4, pages 751-761.
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Juan M. Munoz-Guijosa, Genki Nanaumi, Kazuki Ohtani & Naoto Ohtake. (2017) Perpendicular ultrasonic joining of steel to aluminium alloy plates. Journal of Materials Processing Technology 243, pages 112-122.
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He Peng, Daolun Chen & Xianquan Jiang. (2017) Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy. Materials 10:5, pages 449.
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Mantra Prasad Satpathy & Susanta Kumar Sahoo. (2017) Mechanical performance and metallurgical characterization of ultrasonically welded dissimilar joints. Journal of Manufacturing Processes 25, pages 443-451.
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Ziad Sh Al Sarraf & Joan A. Akrawi. (2016) Design, simulation and fabrication of ultrasonic welding device used to improve welding parameters. Design, simulation and fabrication of ultrasonic welding device used to improve welding parameters.
F.A. Mirza, A. Macwan, S.D. Bhole, D.L. Chen & X.-G. Chen. (2016) Effect of welding energy on microstructure and strength of ultrasonic spot welded dissimilar joints of aluminum to steel sheets. Materials Science and Engineering: A 668, pages 73-85.
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Mantra Prasad Satpathy & Susanta Kumar Sahoo. (2016) Microstructural and mechanical performance of ultrasonic spot welded Al–Cu joints for various surface conditions. Journal of Manufacturing Processes 22, pages 108-114.
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Mantra Prasad Satpathy, Bikash Ranjan Moharana, Shailesh Dewangan & Susanta Kumar Sahoo. (2015) Modeling and optimization of ultrasonic metal welding on dissimilar sheets using fuzzy based genetic algorithm approach. Engineering Science and Technology, an International Journal 18:4, pages 634-647.
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P. Jedrasiak, H. R. Shercliff, Y. C. Chen, L. Wang, P. Prangnell & J. Robson. (2014) Modeling of the Thermal Field in Dissimilar Alloy Ultrasonic Welding. Journal of Materials Engineering and Performance 24:2, pages 799-807.
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K. Martinsen, S.J. Hu & B.E. Carlson. (2015) Joining of dissimilar materials. CIRP Annals 64:2, pages 679-699.
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M.P. Matheny & K.F. Graff. 2015. Power Ultrasonics. Power Ultrasonics 259 293 .
S. Shawn Lee, Chenhui Shao, Tae Hyung Kim, S. Jack Hu, Elijah Kannatey-Asibu, Wayne W. Cai, J. Patrick Spicer & Jeffrey A. Abell. (2014) Characterization of Ultrasonic Metal Welding by Correlating Online Sensor Signals With Weld Attributes. Journal of Manufacturing Science and Engineering 136:5.
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Mantra Prasad Satpathy, Susant Kumar Sahoo & Saurav Datta. (2014) Optimization of Tensile Strength during Ultrasonic Lap Welding of Dissimilar Metals Using Taguchi’s Philosophy. Applied Mechanics and Materials 592-594, pages 652-657.
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M. Shakil, N.H. Tariq, M. Ahmad, M.A. Choudhary, J.I. Akhter & S.S. Babu. (2014) Effect of ultrasonic welding parameters on microstructure and mechanical properties of dissimilar joints. Materials & Design 55, pages 263-273.
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Michele Carboni. (2014) Failure analysis of two aluminium alloy sonotrodes for ultrasonic plastic welding. International Journal of Fatigue 60, pages 110-120.
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Hongjun Ji, Junzhao Wang & Mingyu Li. (2014) Evolution of the bulk microstructure in 1100 aluminum builds fabricated by ultrasonic metal welding. Journal of Materials Processing Technology 214:2, pages 175-182.
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Michele Carboni & Fabrizio Moroni. (2011) Tensile-Shear Fatigue Behavior of Aluminum and Magnesium Lap-Joints obtained by Ultrasonic Welding and Adhesive Bonding. Procedia Engineering 10, pages 3561-3566.
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