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Ultrasonic metal welding is an energy-efficient, fast and clean joining technology without the need of additional filler materials. Single spot ultrasonic metal welding of aluminum to steel sheets using automotive materials has already been investigated. Up to now, further studies to close the gap to application-relevant multi-metal structures with multiple weld spots generated are still missed. In this work, two different spot arrangements are presented, each consisting of two weld spots, joined 0.9 mm thick sheets of wrought aluminum alloy AA6005A-T4 with 1 mm sheets of galvannealed (galvanized and annealed) dual-phase steel HCT980X. An anvil equipped with variable additional clamping punches was used for the first time. The tensile shear forces reached 4076 ± 277 N for parallel connection and 3888 ± 308 N for series connection. Temperature measurements by thermocouples at the interface and through thermal imaging presented peak temperatures above 400 °C at the multi-metal interface. Microscopic investigations of fractured surfaces identified the Zn layer of the steel sheets as the strength-limiting factor. Energy-dispersive X-ray spectroscopy (EDX) indicated intermetallic phases of Fe and Zn in the border areas of the weld spots as well as the separation of the zinc layer from the steel within these areas.

Multi-Spot Ultrasonic Welding of Aluminum to Steel Sheets: Process and Fracture Analysis