Evolution of bonding interface during ultrasonic welding between steel and aluminium alloy

Ultrasonic welding (USW), a solid-state bonding technique, was applied to join ultra-low carbon steel and Al5052 aluminium alloy. The evolution of bonding strength and microstructure at the bonding interface during ultrasonic welding was investigated with an emphasis on the early stage before the formation of intermetallic compound. Initially, adhesive wear starts when steel and Al alloy have sliding contact, and thereafter, a thin layer of Al is attached onto the surface of the steel while the wear of Al base metal is continued owing to the sliding. As the welding time increases, bonding sections are gradually formed with the increase of interfacial temperature owing to the sliding friction, whose process is illustrated in this article.