Mechanical Behavior and Microstructure of Ultrasonic-Spot-Welded Al/Cu Dissimilar Joints with Zn Interlayer

  • Chunjie Li
  • Sansan AoEmail author
  • Anqi Wang
  • Qi Wei
  • Manpeng Wu
  • Zhen Luo
Research Article


The effect of Zn interlayer on the microstructural evolution and mechanical behavior of dissimilar ultrasonic-spot-welded Al/Cu joints was investigated. The tensile lap shear strength in relation to welding energy was analyzed. The experimental results show that two intermetallic compounds, Cu5Zn8 and Al2Cu, were generated at the interface of the ultrasonic-spot-welded Al/Cu joint with a Zn interlayer. The primary joining mechanisms of the joint included the intermetallic compound bonding and metallic bonding caused by solid shear plastic deformation. Meanwhile, with increasing welding energy, the plastic deformation of the material became more substantial. With increasing welding energy, the tensile lap shear strength of the joints first increased and then decreased for the ultrasonic-spot-welded Al/Cu joints with and without Zn interlayers. Under the energy input of 700 J, the bearing load capacity of the ultrasonic-spot-welded Al/Cu joints with a Zn interlayer improved significantly due to the observed intermetallic compound (Cu5Zn8).


Zn interlayer Ultrasonic spot welding Dissimilar joints Plastic deformation Welding energy 



This study was supported by the National Key R&D Program of China (2018YFB1107900), the National Natural Science Foundation of China and Civil Aviation Administration of China (U1933129), the Natural Science Foundation of Tianjin City (18JCQNJC04100), and the National Natural Science Foundation of China (51575383).


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Copyright information

© Tianjin University and Springer-Verlag GmbH Germany, part of Springer Nature 2019

Authors and Affiliations

  • Chunjie Li
    • 1
  • Sansan Ao
    • 1
    Email author
  • Anqi Wang
    • 1
  • Qi Wei
    • 1
  • Manpeng Wu
    • 1
  • Zhen Luo
    • 1
  1. 1.School of Materials Science and EngineeringTianjin UniversityTianjinChina

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