Process robustness of single lap ultrasonic welding of thin, dissimilar materials

Fusion welding processes, such as resistance welding and laser welding, face difficulties in welding thin layers of dissimilar materials. Ultrasonic welding overcomes many of these difficulties by using high frequency vibration and pressure to input energy into the affected area to create a solid state weld. This paper presents a process robustness study of ultrasonic welding of thin metal sheets. Quality of the welded joints is evaluated based on mechanical tests and the quality criterion is then applied to evaluate the weldability. These results were used to determine both the optimal weld parameters and the robust operating range.