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<p>Ultrasonic metal welding (USMW) is a major solid-state joining technique for assembling lithium-ion battery cells due to its advantages in joining dissimilar, highly conductive, and thin sheet materials. However, current research on the USMW process model mainly focuses on a single aspect, such as material interactions at the weld interface. Thus, an integrated study of the welding process from multiple perspectives is required for a comprehensive understanding of the welding process and the underlying bonding mechanisms. Based on the experimental results from our previous works, a five-stage empirical model for USMW of Al/Cu joints was built and presented in this study, which includes ramp-up, extensive interaction, formation of a macroscopical joint, improvement of joint strength, and overwelding. Additionally, a special situation in which static friction at the weld interface was investigated through welding experiments with an increased welding force. This supplementary investigation revealed a similar process sequence without extensive friction work between two joining partners, which also resulted in the formation of a macroscopic Al/Cu joint.</p>

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Empirically based process model approach for ultrasonic metal welding of Al/Cu joints

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Junqi Li,
  • Frank Balle

摘要

Ultrasonic metal welding (USMW) is a major solid-state joining technique for assembling lithium-ion battery cells due to its advantages in joining dissimilar, highly conductive, and thin sheet materials. However, current research on the USMW process model mainly focuses on a single aspect, such as material interactions at the weld interface. Thus, an integrated study of the welding process from multiple perspectives is required for a comprehensive understanding of the welding process and the underlying bonding mechanisms. Based on the experimental results from our previous works, a five-stage empirical model for USMW of Al/Cu joints was built and presented in this study, which includes ramp-up, extensive interaction, formation of a macroscopical joint, improvement of joint strength, and overwelding. Additionally, a special situation in which static friction at the weld interface was investigated through welding experiments with an increased welding force. This supplementary investigation revealed a similar process sequence without extensive friction work between two joining partners, which also resulted in the formation of a macroscopic Al/Cu joint.