Weldability and mechanical properties of ultrasonic joining of aluminum to copper alloy with an interlayer

Al/Cu joints with Al2219 alloy particle as an interlayer were successfully achieved using ultrasonic spot welding (USW) with different welding time and amplitude. Effects of welding parameters on the lap shear tensile strength of the joints were investigated. Based on the results, a sound Al/Cu joint was obtained, without gaps in the interface of Cu/interlayer. Compared with the conventional welding, plastic deformation in the copper side was greater and the lap shear tensile strength was higher. Welding parameters were optimized, and the lap shear tensile strength was highest when the welding time was 0.45 s and the amplitude was 45 µm.