Ultrasonic energy welds copper to aluminium

Journal Article · Wed Jan 01 04:00:00 EST 1997 · Welding Journal

OSTI ID:419748

Flood, G ^[1]

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1. American Technology, Inc., Shelton, CT (United States)

Attempting to weld copper to aluminum by conventional means through the application of thermal energy to melt and fuse the two metals (fusion welding) can result in an unreliable weld. The oxide layer on aluminum is difficult to remove, the melt temperatures of the two metals are not close, the two metals exhibit high thermal conductivity and alloying of the two metals creates a brittle intermetallic that is mechanically and electrically unreliable. An alternative for design engineers is to weld copper to aluminum by applying ultrasonic energy, which joins the metals without melting. The ultrasonic process creates a high quality weld both mechanically and electrically without forming a brittle intermetallic and without intermediate steps. Ultrasonic welding of copper to aluminum has been shown to be efficient and effective as demonstrated by a number of practical production applications. The problems of tough oxides, high thermal conductivity, high electrical conductivity, intermetallics and brittle alloys are not significant with the ultrasonic welding process. And similarly, the problems associated with pre and postweld cleaning, fluxes, hot metal and high energy costs are eliminated. Modern ultrasonic welding equipment is capable of monitoring energy and controlling the critical welding process variables.

• OSTI ID: 419748
• Journal Information: Welding Journal, Journal Name: Welding Journal Journal Issue: 1 Vol. 76; ISSN 0043-2296; ISSN WEJUA3
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
ALUMINIUM
COPPER
PROCESS CONTROL
ULTRASONIC WELDING
USES
WELDING MACHINES