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<p>We present a study of ultrasonically welded Al wire/Cu plate joints with novel plowing-induced patterning. Various plowing-induced surfaces were machined on Cu plate to improve the bonding mechanism of welded joints. The PS-4 group exhibited upgraded interfacial bonding, achieving an interface strength and maximum peel strength of 2605 N and 2349 N respectively. The maximum UTS value reached 96 MPa in stress/strain tests. Conductivity analysis showed welds in the PS-4 group had low resistivity (0.008–0.009 mΩ). Weld quality was poor in samples 2 and 3, where high-frequency ultrasonic signals decayed rapidly due to groove addition. In contrast, welds in samples 1 and 4 indicated better quality with slower signal decay. SEM analysis revealed dense, compact interfaces under 1600 J welding energy with no voids or irregularities. EDS scans showed 14.6% carbon content in horizontal positions and 10.5% in plowed areas. EBSD analysis of the SP-4 sample indicated that&#xa0;grain boundary distribution and texture planes&#xa0;were parallel to the rolling direction with a maximum grain size of 3.4 μm.</p>

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Ultrasonically welded joint strength, fracture, and microstructure evolution using plowing-induced patterning

  • 期刊论文

  • 发表日期：

    2025年9月20日

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  • Zeshan Abbas,
  • Lun Zhao,
  • Dan Chen,
  • Jianxiong Su,
  • He Shengli,
  • Lan Zhang,
  • Haoran Cheng,
  • Xiaozhi Qi

摘要

We present a study of ultrasonically welded Al wire/Cu plate joints with novel plowing-induced patterning. Various plowing-induced surfaces were machined on Cu plate to improve the bonding mechanism of welded joints. The PS-4 group exhibited upgraded interfacial bonding, achieving an interface strength and maximum peel strength of 2605 N and 2349 N respectively. The maximum UTS value reached 96 MPa in stress/strain tests. Conductivity analysis showed welds in the PS-4 group had low resistivity (0.008–0.009 mΩ). Weld quality was poor in samples 2 and 3, where high-frequency ultrasonic signals decayed rapidly due to groove addition. In contrast, welds in samples 1 and 4 indicated better quality with slower signal decay. SEM analysis revealed dense, compact interfaces under 1600 J welding energy with no voids or irregularities. EDS scans showed 14.6% carbon content in horizontal positions and 10.5% in plowed areas. EBSD analysis of the SP-4 sample indicated that grain boundary distribution and texture planes were parallel to the rolling direction with a maximum grain size of 3.4 μm.