Effects of Sonotrode Geometry on Welding Temperature Field and Plastic Deformation in Cu/Al High-power Ultrasonic Welding
LI Huan1,*, ZHANG Jian1, WU Shiying2, LIU Qianxi1
1 School of Mechanical Engineering, Yangtze University, Jingzhou 434023, Hubei, China 2 School of Mechanical and Electronics, Guangzhou Railway Polytechnic, Guangzhou 510430, China
Abstract: The geometry of the sonotrode tip is an important parameter of ultrasonic welding, but the influence of the welding head geometry on the wel-ding process is insufficient currently. A three-dimensional sound-thermal-mechanical field coupling model was established using the finite element method. The influence of tooth spacing and angle on interface temperature, interface plastic deformation and microstructures, and sonotrode downward displacement during Cu/Al high power ultrasonic welding was mainly investigated. The results showed that when the spacing of the sonotrode tooth was 0.9 mm, the joint was well formed without obvious defects, and the higher interface temperature promoted the growth of the intermetallic compound. When the spacing of the tooth was 0.8 mm or 1.0 mm, the plastic strain of the material below the edge of the sonotrode was significantly higher, resulting in the production and expansion of the crack. As the sonotrode teeth angle increased from 108° to 135°, the interface temperature decreased from 471.9 ℃ to 456.3 ℃, the sonotrode displacement decreased from 0.344 mm to 0.304 mm, and the maximum plastic strain of specimens sharply decreased from 0.94 to 0.63. This research should provide a theoretical reference of optimizing the welding geometry.
李欢, 张健, 伍世英, 刘千喜. 焊头形状对Cu/Al大功率超声焊接温度场及塑性变形的影响[J]. 材料导报, 2025, 39(6): 24010115-6.
LI Huan, ZHANG Jian, WU Shiying, LIU Qianxi. Effects of Sonotrode Geometry on Welding Temperature Field and Plastic Deformation in Cu/Al High-power Ultrasonic Welding. Materials Reports, 2025, 39(6): 24010115-6.
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2025, Vol. 39 
