Li Zhe, Wu Shiying, Li Huan
School of Electromechanical, Guangzhou Railway Polytechnic, Guangzhou 511300, China.
School of Mechanical Engineering, Yangtze University, Jingzhou 434000, China.
Micromachines (Basel). 2025 Feb 26;16(3):263. doi: 10.3390/mi16030263.
Ultrasonic welding is characterized by its energy-saving and environmentally friendly nature. Compared to conventional molten welding technology, the intermetallic compounds formed by diffusion during ultrasonic welding are thinner, and material deformation is reduced. This process has become a primary welding technique for assembling lithium batteries in electric vehicles. Aluminum and copper ultrasonic welding has increasingly gained attention as a research hotspot. The research on aluminum and copper ultrasonic welding primarily focuses on the interfacial microstructure evolution, mechanical performance during the welding process, and numerical simulations to investigate macro- and micro-scale physical phenomena. Given the aluminum and copper multi-layer structures used in lithium battery packaging, numerous studies have been conducted on aluminum and copper multi-layer ultrasonic welding. For Al/Cu joints, advancements in understanding the microstructure evolution, joint performance, and finite element modeling of the welding process have been systematically reviewed and summarized. Moreover, significant progress has been made in molecular dynamics simulations of Al/Cu ultrasonic welding and hybrid welding techniques based on Al/Cu ultrasonic welding. Finally, several new research directions for Al/Cu ultrasonic welding and joining have been proposed to guide further in-depth studies.
超声焊接具有节能和环保的特点。与传统的熔焊技术相比，超声焊接过程中通过扩散形成的金属间化合物更薄，材料变形也更小。这一工艺已成为电动汽车锂电池组装的主要焊接技术。铝和铜的超声焊接作为一个研究热点越来越受到关注。铝和铜超声焊接的研究主要集中在界面微观结构演变、焊接过程中的力学性能以及用于研究宏观和微观物理现象的数值模拟。鉴于锂电池封装中使用的铝和铜多层结构，人们对铝和铜多层超声焊接进行了大量研究。对于铝/铜接头，在理解微观结构演变、接头性能以及焊接过程的有限元建模方面的进展已得到系统的综述和总结。此外，铝/铜超声焊接的分子动力学模拟以及基于铝/铜超声焊接的混合焊接技术也取得了显著进展。最后，提出了铝/铜超声焊接与连接的几个新研究方向，以指导进一步的深入研究。
