Ultrasonic Resistance Spot Welding of Thin Metal Foils

摘要

Traditional welding methods, such as laser , resistance spot and/or ultrasonic welding, are commonly used for joining thin-gauge metals in manufacturing industry. However, when the base metals are extremely thin, for instance, around 15-micrometer thick aluminum foils, the weak connection (or defects) of the welds by above methods, is always present due to the presence of aluminum oxide and air gaps. The present disclosure relates to a new welding method - ultrasonic resistance spot welding (URSW), that is able to produce a defect-free weld for stack-ups with thin metal foils.