Ultrasonic welding has enormous potential for the production of multi-material systems due to its short process time, low energy requirements and a wide range of materials that can be joined, including dissimilar materials. In this process, high-frequency mechanical vibrations are used to generate friction-like relative movements between the material surfaces via a vibration system. The contact between the vibration system and the joining zone is made by the so-called sonotrode coupling surface (SCS), the structuring of which is of decisive importance for the resulting bond strength and wear.

The aim of this research project is to develop the joining of titanium alloys using power ultrasound by means of suitable sonotrode geometries and SKF structuring for future lightweight construction applications, particularly with regard to titanium alloys as the upper joining partner. The causal damage and wear processes are studied and modelled using simulation-based experimental analyses in order to develop durable sonotrode concepts with minimum wear and maximum bond strength of Ti joints. In the course of microstructural bond characterisation, the level of knowledge of the bonding mechanism during ultrasonic welding and the correlation between the structure of the interface and the bond strength will be expanded.

Funded by the German Research Foundation