Ultrasonic Welding of Aluminium - An Emerging Automotive Production Process

Ultrasonicaily bonded aluminum sheet metal assemblies have found flight test acceptance in Fairchild Republic's A-10 aircraft. Panel tests show high static and fatigue strength and low deformation with favorable cost and weight factors. Panel assemblies in aluminum alloys of interest to the automotive industry were ultrasonically spot welded; panel strength and single spot strength data are summarized. Relative cost, weight and utility of the ultrasonic versus various other joining methods are assessed.