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Abstract:In this study, a thermal model during continuous ultrasonic welding of thin foils has been developed. The heat generation during the process, stick/slip state, and effect of elastic/plastic strains are included in the formulation. The physics is simplified to a one-dimensional transient heat transfer analysis, the governing equation is nondimensionalized, and important parameters are identified. A fourth-order Runge-Kutta numerical scheme is used to predict the transient temperature as a function of material, constitutive, and process parameters. Comparison with experimental results is provided to justify the assumptions introduced in the model. Different heat generation terms are introduced and their contribution to overall heat generation is presented.