An Experimental Investigation of Ultrasonic Spot Welded Dissimilar Joint of 304SS to Al3003 With Interlayer

Abstract

Solid state ultrasonic spot welding is very popular recently due to its less time requirement, low cost and high energy efficiency in comparison with conventional fusion welding technique. In this investigation USW was used to join Al3003 alloy to 304SS at different clamping pressure, different amplitude and different weld energy levels. Initially, the tensile lap shear strength increased with increasing welding energy, then after certain value it decreases with increase in weld energy and same trend is followed with the amplitude of vibration in ultrasonic welding. The tensile lap shear strength increases with increase in clamping pressure. Two major type of failure mode were observed during tensile lap shear tests, which are interfacial failure and transverse through thickness failure. During USW rapid inter diffusion of Cu, Al and Fe resulted in the formation of IMCs layer occurs which impart strength to the weld joint.