Published Paper Details:

The use of multiple materials in engineering structures is becoming more powerful, particularly in applications such as transportation. Combining different materials allows for more efficient designs and greater performance that could be achieved with a single material, with beneficial impacts for a range of industries. As it produces welds of high quality without the use of filler material, ultrasonic welding can join thin sheets of similar or different non-ferrous alloys, including copper, aluminum, magnesium, and brass. This bond is strong and reliable and can withstand high loads and stresses. These studies evaluate the relationship between the tensile strength of ultrasonic welding of sheets with various welding parameters, such as weld pressure, weld time, and hold time. It has been discovered that lengthening the weld and increasing the welding pressure can strengthen the link between the sheets. The mechanical characteristics of the joint, particularly its tensile strength and fatigue life, have been found to be improved by the application of an interlayer. A copper or zinc interlayer was shown to increase the joint's tensile strength. The enhanced mechanical capabilities are due to the interlayer's capacity to operate as a barrier between the sheets, limiting the production of intermetallic compounds and other flaws that could weaken the joint. This review article discusses the properties of ultrasonic welding, the interface of welding joints, performance, and welding variables for various materials.