Method and system of joining thick sheets of non-weldable material using ultrasonic joining

摘要

A method and system for joining relatively thick (i.e., at least 0.07 inch, or between 0.08 and 0.24 inch) sheets of non-weldable aluminum or other material using multiple passes of ultrasonic joining and multiple plugs to create a single larger sheet. Angles and profiles are machined onto edges of the sheets, the angles are overlapped to form a scarf joint, and ultrasonic joining is performed on both sides of the scarf joint, resulting in channels where the angles and profiles intersect. Plugs are extruded or otherwise created and positioned in the channels, and ultrasonic joining is used to join the plugs in the channels. Additional plugs are added until the last plugs are proud of the surface, and then the plugs are machined until the joint is flush with the surface. The plugs may be of the same or a different material as the sheets.