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<p>Ultrasonic welding of aluminum wires with copper terminals presents significant challenges due to the uneven thermal and mechanical properties of materials, which can lead to unstable joint strength and reliability at the welding interface. This study develops a validated finite element model to simulate the coupled thermomechanical process and experimentally characterizes the quality of resulting joints. A transient thermal FE model was implemented in ANSYS software which includes frictional and plastic deformation heat sources to predict and simulate the evolution of interfacial temperature during welding under optimized parameters (clamping force 4&#xa0;MPa, frequency 20&#xa0;kHz, amplitude 25&#xa0;μm). The simulation predicted a maximum interface temperature of 486.12&#xa0;°C in 0.08&#xa0;s, reaching 85% of the Al-Cu eutectic point which is suitable for the welding process. Experimental validation using K-type thermocouples embedded in the welded samples showed excellent agreement with an average maximum temperature of 480.5&#xa0;°C (1.2% error) and a correlation coefficient of R²=0.890. In addition, tensile testing revealed a range of joint strengths of 1846–2432&#xa0;N with higher strength samples correlating with optimal temperature profiles. Microstructural analysis via SEM and EDS confirmed effective solid-state diffusion with a 10–20&#xa0;μm wide mixing zone at the interface. This integrated simulation-experimental approach provides a reliable framework for predicting and optimizing ultrasonic welding parameters and further improves the durability of welded joints for critical applications such as automotive electrical systems.</p>

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Validated thermomechanical modeling of interfacial temperature and joint performance in ultrasonic welding of Al wire to Cu terminal for automotive applications

  • 期刊论文

  • 发表日期：

    2026年6月15日

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  • Qiang Huang,
  • Lun Zhao,
  • Zeshan Abbas,
  • Qianghua Liao,
  • Liya Li,
  • Jiajin Zhang,
  • Shengli He,
  • Muhammad Waqas

摘要

Ultrasonic welding of aluminum wires with copper terminals presents significant challenges due to the uneven thermal and mechanical properties of materials, which can lead to unstable joint strength and reliability at the welding interface. This study develops a validated finite element model to simulate the coupled thermomechanical process and experimentally characterizes the quality of resulting joints. A transient thermal FE model was implemented in ANSYS software which includes frictional and plastic deformation heat sources to predict and simulate the evolution of interfacial temperature during welding under optimized parameters (clamping force 4 MPa, frequency 20 kHz, amplitude 25 μm). The simulation predicted a maximum interface temperature of 486.12 °C in 0.08 s, reaching 85% of the Al-Cu eutectic point which is suitable for the welding process. Experimental validation using K-type thermocouples embedded in the welded samples showed excellent agreement with an average maximum temperature of 480.5 °C (1.2% error) and a correlation coefficient of R²=0.890. In addition, tensile testing revealed a range of joint strengths of 1846–2432 N with higher strength samples correlating with optimal temperature profiles. Microstructural analysis via SEM and EDS confirmed effective solid-state diffusion with a 10–20 μm wide mixing zone at the interface. This integrated simulation-experimental approach provides a reliable framework for predicting and optimizing ultrasonic welding parameters and further improves the durability of welded joints for critical applications such as automotive electrical systems.