Ultrasonic Spot Welded Dissimilar Joint of AISI 304SS to CP-Copper Sheets with Inter Layer: An Experimental Investigation

Ultrasonic welding is used to join stainless steel with CP-copper using an interlayer. Two different interlayers, aluminum and brass are used. Tensile shear test was conducted in order to find better interlayer among them. As Brass provided good results, further experiments are carried out using full factorial design of experiments with three variables (amplitude of vibration, weld pressure and weld time) with three levels of each. Tensile shear test and Tpeel test was conducted. The formation of intermetallic at the failure interface was studied by X-Ray Diffraction. The variation of strength was studied and ANNOVA was conducted to study the impact of the welding parameter on weld strength. Good weld is obtained by welding keeping copper on top (i.e. sonotrode side)