Effect of the interface characteristics on the joint properties and diffusion mechanisms during ultrasonic metal welding of Al/Cu

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

“…By applying processes like electromagnetic pulse welding [18], ultrasonic welding [19,20], and friction stir welding [21], the IMC formation can be minimized successfully. Friction welding and friction stir welding, which can be defined as heat and forge type processes as described by Gould [22], are especially suitable for dissimilar joints, as the high applied strain under elevated temperature allows the displacement of oxides and containments and rapid bond formation in solid state by recrystallization.…”

Influence of different Ni coatings on the long-term behavior of ultrasonic welded EN AW 1370 cable/EN CW 004A arrestor dissimilar joints

“…Since the conductivity of aluminum is lower than that of copper, the cross section of aluminum conductors must be increased by approximately 60%. Despite the increase in the conductor cross section, it is possible to achieve a theoretical weight saving up to 50% [2]. Due to the properties of aluminum, such as the creep behavior and its oxide layer, the substitution can only be partial.…”

“…This is achieved either by specific insulation of the joint by using protective plastic sealing or by the use of suitable coating of the copper elements. Nickel coatings, which act as a diffusion barrier between aluminum and copper, are frequently used for this purpose and can thus reduce corrosion [2]; [22]; [23]; [24]; [25]. These coatings can be distinguished by the type of nickel coating process, the composition of the electrolytes, the composition of the coating and the mechanical, chemical, and tribological properties.…”

“…Furthermore, Oberst et al investigated the influence of different temperature loads on the building rates of IMCs for Al/Cu joints, Al/Ni/Cu joints as well as other material combinations in order to determine a maximum temperature at which the connections can be used [29]. Bergmann et al studied the influence of thermal load tests on ultrasonic welded aluminum wire-copper terminal connections considering different nickel coatings [2]. In their research, the welded samples were exposed to a thermal load of 350°C for 45 h. The authors showed a reduced failure load of up to 43% for nickel-plated samples and a reduced failure load of 60% for Al/Cu joints without coating [2].…”

“…Bergmann et al studied the influence of thermal load tests on ultrasonic welded aluminum wire-copper terminal connections considering different nickel coatings [2]. In their research, the welded samples were exposed to a thermal load of 350°C for 45 h. The authors showed a reduced failure load of up to 43% for nickel-plated samples and a reduced failure load of 60% for Al/Cu joints without coating [2].…”