The effects of welding parameters on ultrasonic spot welding of dissimilar Al 3105 and Al 1050 alloys

Al 1050 and Al 3105 aluminum alloy sheets were joined via ultrasonic spot welding (USW). Due to mechanical and thermal cycles during USW, both diffusion and mechanical mixing facilitated the formation of welded interfaces. The alloying element, Mn, in Al 3105 diffused into Al 1050 during USW, and diffusion behavior varied with selection of top sheet. The fracture mechanism during lap shear testing, i.e.debonding or pullout fracture, varied based on welding power, time and pressure.

Keywords:

Al 1050 and Al 3105 alloys , ultrasonic spot welding , horn