Ultrasonic Welding of Aluminum to Steel: A Review

As a solid-state bonding technology, ultrasonic welding (USW) has the characteristics of green energy saving and environmental friendliness. It is more suitable for joining dissimilar metals than other welding technologies. The aluminum-to-steel USWed joint has been widely used in the automotive and aviation industries. Currently, there is no review literature report on aluminum-to-steel USW. The main physical phenomena of the USW process include interface temperature increase, ultrasonic softening, plastic deformation, formation and growth of the IMCs, and dynamic recrystallization. Hence, the microstructures and mechanical properties of aluminum-alloy-to-low-carbon-steel, aluminum-alloy-to-stainless steel, and aluminum-alloy-to-galvanized-steel-joints by USW are reviewed. Moreover, the effect of interface temperature, interface plastic deformation, and interface macrostructure and microstructure is explored. Lastly, tensile-shear and fatigue strength of joints and numerical simulation of the USW process are also discussed. In addition, some new application types of aluminum-to-steel USW are introduced. Finally, the future trends of aluminum-to-steel USW with guidance are provided.

Automated summary

As a solid-state bonding technology, ultrasonic welding (USW) is environmentally friendly and energy saving, making it more suitable for joining dissimilar metals than other welding technologies. Aluminum-to-steel USWed joint is widely used in automotive and aviation industries. This review explores the microstructures, mechanical properties, and factors influencing aluminum-alloy-to-low-carbon-steel, aluminum-alloy-to-stainless steel, and aluminum-alloy-to-galvanized-steel-joints by USW. It also discusses the tensile-shear and fatigue strength of joints, numerical simulation of the USW process, and introduces new application types. Future trends of aluminum-to-steel USW are also provided.