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<p>Aluminum-copper dissimilar metal lap joints were prepared using ultrasonic welding technology. This study investigated the influence of varying copper plate surface roughness on thermal behavior during welding, interfacial bonding characteristics, mechanical properties, and failure modes. These aspects were analyzed using infrared thermography, tensile shear testing, and scanning electron microscopy (SEM). Results indicated that Grit-60 joints exhibited the smallest peak temperature at weld edge, approximately 131&#xa0;°C, whereas Grit-2000 joints reached a maximum of 150&#xa0;°C. Macroscopic cross-sectional morphology revealed no visible defects for any roughness level. EDS surface analysis further demonstrated that increased copper surface roughness led to a more convoluted microscopic weld morphology at bonding interface. Concurrently, the Grit-2000 joint exhibited highest degree of interdiffusion with a diffusion width of approximately 1.81&#xa0;μm. The average tensile shear strength of Grit-60 joints was 3610.17&#xa0;N, while Grit-2000 joints achieved approximately 4700.96&#xa0;N, representing a significant 23.20% increase in strength. Conversely, the Grit-60 weld periphery showed more dispersed aluminum residue and numerous associated cracks. Fracture surface analysis of Grit-2000 joints revealed numerous small, equiaxed dimples, suggesting a mixed ductile-brittle fracture mode. This research provides valuable insights for optimizing ultrasonic welding processes to achieve high- strength and reliable aluminum-copper joints, which are critical for applications in electric vehicles, battery manufacturing, power electronics, and renewable energy systems.</p>

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Surface Roughness Effects on Aluminum-Copper Ultrasonic Dissimilar Welds: Interface, Strength, and Failure Analysis

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • Lun Zhao,
  • Liya Li,
  • Zeshan Abbas,
  • Lan Zhang,
  • Jianxiong Deng,
  • Zhengqiang Tang,
  • Jianxiong Su

摘要

Aluminum-copper dissimilar metal lap joints were prepared using ultrasonic welding technology. This study investigated the influence of varying copper plate surface roughness on thermal behavior during welding, interfacial bonding characteristics, mechanical properties, and failure modes. These aspects were analyzed using infrared thermography, tensile shear testing, and scanning electron microscopy (SEM). Results indicated that Grit-60 joints exhibited the smallest peak temperature at weld edge, approximately 131 °C, whereas Grit-2000 joints reached a maximum of 150 °C. Macroscopic cross-sectional morphology revealed no visible defects for any roughness level. EDS surface analysis further demonstrated that increased copper surface roughness led to a more convoluted microscopic weld morphology at bonding interface. Concurrently, the Grit-2000 joint exhibited highest degree of interdiffusion with a diffusion width of approximately 1.81 μm. The average tensile shear strength of Grit-60 joints was 3610.17 N, while Grit-2000 joints achieved approximately 4700.96 N, representing a significant 23.20% increase in strength. Conversely, the Grit-60 weld periphery showed more dispersed aluminum residue and numerous associated cracks. Fracture surface analysis of Grit-2000 joints revealed numerous small, equiaxed dimples, suggesting a mixed ductile-brittle fracture mode. This research provides valuable insights for optimizing ultrasonic welding processes to achieve high- strength and reliable aluminum-copper joints, which are critical for applications in electric vehicles, battery manufacturing, power electronics, and renewable energy systems.