Ultrasonic welding between mild steel sheet and Al–Mg alloy sheet

Ultrasonic welding between SS400 mild steel sheet and aluminum alloy sheet containing magnesium (A5052) was conducted. In this study, authors investigated the influence of ultrasonic welding conditions on the mechanical properties and the interface microstructure of a joint, and the effect of insert metal was examined to improve the joint strength. The main results obtained in this study are as follows. It was possible to weld ultrasonically SS400 mild steel sheet to A5052 aluminum alloy sheet containing magnesium. The strength of the joints welded using various clamping forces and constant welding time of 1.0 s showed the maximum value at the clamping force of 588 N and decreased with the clamping force over 588 N because the excessively large clamping force reduced the frictional action at the interface. The strength of the joints welded using the constant clamping force of 588 N and various welding times showed the maximum value at the welding time of 2.5 s. However, the strength of the joint welded using the welding time of 3.0 s decreased due to the formation of Fe2Al5 intermetallic compound at the interface. Using the insert metal of commercially pure aluminum, the joint strength was successfully improved and the strength of the welded using 3.0 s welding time was about three times as large as that of the joint without the insert metal.