Interface microstructure and formation mechanism of ultrasonic spot welding for Al-Ti dissimilar metals

The present study focuses on interface microstructure and joint formation. AA6061 aluminum alloy (Al) and commercial pure titanium (Ti) joints were welded by ultrasonic spot welding (USW). The welding energy was 1100–3200 J. The Al-Ti joint appearance and interface microstructure were observed mainly via optical microscopy and field emission scanning electron microscopy. Results indicated that a good joint can be achieved only with proper welding energy of 2150 J. No significant intermetallic compound (IMC) was found under all conditions. The high energy barriers of Al-Ti and difficulties in diffusion were the main reasons for the absence of IMC according to kinetic analysis. The heat input is crucial for the material plastic flow and bonding area, which plays an important role in the joint formation.