Application of Ultrasonic Welding for Dissimilar Metals: A Review

Ultrasonic welding is successfully used for similar metals. Welding of dissimilar metals faces difficulties like differences in physical and mechanical properties, melting temperature and development of intermetallic compounds. Dissimilar metals have wide applications in the aerospace, biomedical and automotive industries. This paper aims to review applications of ultrasonic weld of various dissimilar metal combinations. Ultrasonic welding enables to join dissimilar metals with less energy input at lower temperatures compared with other fusion or resistance welding processes. Ultrasonic spot welding can be used for various dissimilar metal combinations with improved joint quality. The interlayer is used for better bonding between two dissimilar metals. Al/SS, Al/Cu, Al/Ni, Al/Mg, Cu/Mg, Mg/Ti and Cu/NPs/Cu joints are successfully formed by using ultrasonic welding.