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<p>Ultrasonic metal welding is widely used in the electronics industry, particularly in the production of lithium batteries, for joining both similar and dissimilar materials. Limited research has been conducted on optimizing welding parameters using statistical software to achieve maximum lap shear strength (LSS). In this study, the effects of welding amplitude, time, and pressure in ultrasonic metal welding were investigated for bonding similar aluminum sheets. Design Expert software and response surface methodology (RSM) were utilized to optimize these parameters and examine their interactions, aiming to maximize joint strength. Additionally, the temperature and microstructure of the joint were analyzed to evaluate and control the influence of welding parameters on the joint strength. Findings revealed that welding time, pressure, and the square of the pressure were the most influential factors affecting joint strength. Macro- and microstructural features of the joint interface were examined, and microstructural changes under various ultrasonic welding conditions were correlated with the joint strength. The formation and propagation of micro-bonding zones emerged as the primary mechanisms of joint formation, while the density of micro-bonding zones increased with welding time and the weld effective thickness decreased. In joints with a maximum temperature of 285&#xa0;°C, greater plastic deformation and softening were observed.</p>

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Microstructural and mechanical characterization of ultrasonic metal welds: insights into micro-bonds formation, dynamic recrystallization, and joint strength optimization

  • 期刊论文

  • 发表日期：

    2025年12月8日

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  • Ali Yusefi,
  • Vahid Allahverdizadeh,
  • Amir Hossein Kokabi,
  • Rezvan Abedini,
  • Vahid Fartashvand

摘要

Ultrasonic metal welding is widely used in the electronics industry, particularly in the production of lithium batteries, for joining both similar and dissimilar materials. Limited research has been conducted on optimizing welding parameters using statistical software to achieve maximum lap shear strength (LSS). In this study, the effects of welding amplitude, time, and pressure in ultrasonic metal welding were investigated for bonding similar aluminum sheets. Design Expert software and response surface methodology (RSM) were utilized to optimize these parameters and examine their interactions, aiming to maximize joint strength. Additionally, the temperature and microstructure of the joint were analyzed to evaluate and control the influence of welding parameters on the joint strength. Findings revealed that welding time, pressure, and the square of the pressure were the most influential factors affecting joint strength. Macro- and microstructural features of the joint interface were examined, and microstructural changes under various ultrasonic welding conditions were correlated with the joint strength. The formation and propagation of micro-bonding zones emerged as the primary mechanisms of joint formation, while the density of micro-bonding zones increased with welding time and the weld effective thickness decreased. In joints with a maximum temperature of 285 °C, greater plastic deformation and softening were observed.