Metal ultrasonic welding (M-USW) can be used to manufacture high-performance multi-material joints. These include material combinations such as Ti/CF-PEEK for high-performance lightweight applications or Al/Cu, which are of great interest to the electronics industry.  In general, ultrasonic welding is characterized by high energy efficiency and short process times. Another advantage over adhesive or bolted joints is that no additional joining-elements are required, which would, for example, increase the component mass or sever continuous fiber reinforcements due to the necessary drill holes.

To date, it is largely unclear which joining mechanisms and interface characteristics in M-USW generate the high joining strengths. This will be fundamentally investigated in this DFG-funded research project using FE models based on optical methods (micro-sections, SEM, and in-situ µCT) and destructive testing methods (see Figure 1). Understanding the mechanism of joining formation is an important milestone in the design of ultrasonically welded multi-material joints.

The objectives of the project are to correlate the formed interface characteristics with the achieved joining strengths. The interfaces are also to be transfered in FE models and the stress states and damage behavior that occur are to be simulated.

Funded by the German Research Foundation (DFG).

For further infomation:

M.Sc. Stefan Buchalik-Bopp

Jun.-Prof. Dr.-Ing Moritz Liesegang