Skip to main content
Have a personal or library account? Click to login
Investigation on the Mechanical Properties of Various Welded Materials by Ultrasonic Welding Technique – A Review Cover

Investigation on the Mechanical Properties of Various Welded Materials by Ultrasonic Welding Technique – A Review

By:  and    
Open Access
|May 2026

References

  1. Sathishkumar S, Pranaybabu K, Naveenkumar K,”A Review on Investigation of Mechanical Properties and Recent Advancements on Ultrasonic Welding”, International Journal of Creative Research Thoughts (IJCRT), ISSN:2320-2882, Volume.11, Issue 5, p.p.k381-k392, May 2023.
  2. Gunduz I, Ando T, Shattuck E, et al. Enhanced diffusion and phase transformations during ultrasonic welding of zinc and aluminum. Scr Mater 2005; 52: 939–943. Available from: https://linkinghub.elsevier.com/retrieve/pii/S1359646204007067. https://doi.org/10.1016/j.scriptamat.2004.12.015.
  3. Al-Sarraf Z. S., “A study of ultrasonic metal welding,” PhD, University of Glasgow, 2013. Available: https://eleanor.lib.gla.ac.uk/record=b2982130.
  4. Feng M, Wang Z, Meng D, Liu C, Hu J, Wang P. A review of quality monitoring for ultrasonic metal welding. Materials Science and Technology. 2024;40(1):3-25. doi:10.1177/02670836231215651.
  5. Al Sarraf Z. S., Saeed M. M. “Design and Analysis of Slotted Block Horn Used for Ultrasonic Power Applications,” J. Southwest Jiao-tong Univ., vol. 54, no. 5, Art. no. 5, 2019, Accessed: Oct. 01, 2022.
  6. Zhao Y Y. Li Dand Zhang Y. S. “Effect of Welding Energy on Interface Zone of Al–Cu Ultrasonic Welded Joint. Sci Technol Weld Joining 2013; 18: 354–360
  7. Harman, G.G., & Albers, J. (1977). The Ultrasonic Welding Mechanism as Applied to Aluminum-and Gold-Wire Bonding in Microelectronics. IEEE Transactions on Parts, Hybrids, and Packaging, 13, 406-412.
  8. Pnteli A, Robson JD, Brough I, et al. The effect of high strain rate deformation on intermetallic reaction during ultrasonic welding aluminium to magnesium. Mater Sci Eng: A 2012; 556: 31–42.
  9. Panteli A, Chen Y-C, Strong D, et al. Optimization of aluminiumto-magnesium ultrasonic spot welding. JOM 2012; 64: 414–420.
  10. Patel V. K, Bhole S. D. and Chen D. L. “Microstructure and mechanical properties of dissimilar welded Mg–Al joints by ultrasonic spot-welding technique”. Sci Technol Weld Joining 2012; 17: 202–206.
  11. Venkatalaxmi A, Padmavathi BS and Amaranath T. A general solution of unsteady Stokes equations. Fluid Dyn Res 2004; 35: 229–236.
  12. Zhu Z, Lee K. Y. and Wang X. Ultrasonic welding of dissimilar metals, AA6061 and Ti6Al4 V. Int J Adv Manufacturing Technology, 2012; 59: 569–574.
  13. Zhang C. Q, Robson J. D. and Prangnell PB. Dissimilar ultrasonic spot welding of aerospace aluminum alloy AA2139 to titanium alloy TiAl6V4. J Mater Process Technol 2016; 231: 382–388.
  14. Zhang H. M, Chao YJ and Luo Z. Effect of interlayer on microstructure and mechanical properties of Al–Ti ultrasonic welds. Sci Technol Weld Joining 2017; 22: 79–86.
  15. Mirza FA, Macwan A, Bhole SD, et al. Effect of welding energy on microstructure and strength of ultrasonic spot-welded dissimilar joints of aluminum to steel sheets. Mater Sci Eng A 2016; 668: 73–85.
  16. Villegas, Irene Fernandez, and Regis van Moorleghem. “Ultrasonic welding of carbon/epoxy and carbon/PEEK composites through a PEI thermoplastic coupling layer.” Composites Part A: Applied Science and Manufacturing 109 (2018): 75-83.
  17. Deekshant Varshney K., (2021), ‘Application and use of different aluminium alloys with respect to workability, strength and welding parameter optimization’, Ain Shams Engineering Journal, Vol. 12, pp. 1143-1152.
  18. Tariq H., (2014), ‘Effect of ultrasonic welding parameters on microstructure and mechanical properties of dissimilar joints’, Materials & Design, Vol. 55, pp. 263-273.
  19. Deekshant Varshney K., (2021), ‘Application and use of different aluminium alloys with respect to workability, strength and welding parameter optimization’, Ain Shams Engineering Journal, Vol. 12, pp. 1143-1152.
  20. Macwan A., Jiang X.Q., And Chen D.L. (2015), ‘Microstructure and mechanical properties of ultrasonic spot-welded copper-to-magnesium alloy joints’, Materials & Design, Vol.84, pp. 261-269.
  21. Harthoorn J. L, (1978), “Ultrasonic Metal Welding”, PhD Thesis, Eindhoven University of Technology.
  22. Bloss M., (2008), “Ultrasonic Metal Welding: The Weldability of Stainless Steel, Titanium and Nickel-Based Super Alloys”, PhD Thesis, University of Ohio.
  23. De Vries, E. Mechanics and Mechanisms of Ultrasonic Metal Welding. Ph.D. Thesis, Ohio State University, Columbus, OH, USA, 2004.
  24. Li, C., Ao, S., Wang, A. et al. “Mechanical Behavior and Microstructure of Ultrasonic-Spot-Welded Al/Cu Dissimilar Joints with Zn Interlayer”. Trans. Tianjin Univ. 26, 305–313 (2020). https://doi.org/10.1007/s12209-019-00221-y.
  25. Basak S., and Kumar S., (2021), ‘Experimental Investigation on Ultrasonic Welding of Similar and Dissimilar Thermoplastics: A Review’, Polymers and Polymer Composites, Vol.29, pp.289-307.
  26. Felice R., Hetal P., Vitantonio E., and Pierpaolo C., (2020) ,‘Ultrasonic welding of magnesium alloys: a review’, Materials and Manufacturing Processes, Vol.35, pp.1051-1068.
  27. Ward, Austin A., Matthew R. French, Donovan N. Leonard, and Zachary C. Cordero. “Grain growth during ultrasonic welding of nanocrystalline alloys.” Journal of Materials Processing Technology 254 (2018): 373-382.
  28. Wu, Kanglong, Xinjian Yuan, Ting Li, Haodong Wang, Chuan Xu, and Jun Luo. “Effect of ultrasonic vibration on TIG welding– brazing joining of aluminum alloy to steel.” Journal of Materials Processing Technology 266 (2019): 230-238.
  29. Zhou, Siyu, Guangyi Ma, Wu Dongjiang, Dongsheng Chai, and Mingkai Lei. “Ultrasonic vibration assisted laser welding of nickel-based alloy and Austenite stainless steel.” Journal of Manufacturing Processes 31 (2018): 759-767.
  30. Lin, Jhe-Yu, Shoichi Nambu, Mao Liu, and Toshihiko Koseki. “Influence of Al and Ni interlayers on interfacial strength evolution during ultrasonic welding of ultra-low-carbon steel and pure Ti.” Materials Science and Engineering: A (2020): 140073.
  31. Youns A. D, Al Sarraf Ziad. S, Hamid Abdulhaqq, Al Dabbagh Zaid T, “Optimal Multi-stepped Sonotrode Design for Ultrasonic Plastic Welding,” International Journal of Mechanical Engineering and Robotics Research, Vol. 14, No. 3, pp. 238-244, 2025. doi: 10.18178/ijmerr.14.3.238-244.
  32. Zhao, Dewang, Kunmin Zhao, Daxin Ren, and Xinglin Guo. “Ultrasonic welding of magnesium–titanium dissimilar metals: A study on influences of welding parameters on mechanical property by experimentation and artificial neural network.” Journal of Manufacturing Science and Engineering 139, no. 3 (2017).
  33. Zhou, L., J. Min, W. X. He, Y. X. Huang, and X. G. Song. “Effect of welding time on microstructure and mechanical properties of Al-Ti ultrasonic spot welds.” Journal of Manufacturing Processes 33 (2018): 64-73.
  34. Rubino, Felice, Hetal Parmar, Vitantonio Esperto, and Pierpaolo Carlone. “Ultrasonic welding of magnesium alloys: a review.” Materials and Manufacturing Processes (2020): 1-18.
  35. Ren, Daxin, Kunmin Zhao, Min Pan, Ying Chang, Song Gang, and Dewang Zhao. “Ultrasonic spot welding of magnesium alloy to titanium alloy.” Scripta Materialia 126 (2017): 58-62.
  36. Anmar Musaid Nayif, Younis A. D., Ziad Shakeeb Al Sarraf, “Investigation of the Process Parameters in Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminum Alloy Joints on Fatigue Initiation using FEA and ANN,” WSEAS Transactions on Applied and Theoretical Mechanics, vol. 19, pp. 97-112, 2024, DOI:10.37394/232011.2024.19.11.
  37. Patel VK, Bhole SD and Chen DL. “Microstructure and mechanical properties of dissimilar welded Mg–Al joints by ultrasonic spot-welding technique”. Sci Technol Weld Joining 2012;17: 202–206.
  38. Feng M-N and Luo Z. Interface morphology and microstructure of high-power ultrasonic spot-welded Mg/Al dissimilar joint. Sci Technol Weld Joining 2019; 24: 63–78.
  39. R. Balasundaram, V.K. Patel, S.D. Bhole, D.L. Chen, “Effect of zinc interlayer on ultrasonic spot-welded aluminum-to-copper joints, Materials Science and Engineering”: A, Volume 607, 2014, Pages 277-286, ISSN 0921-5093, https://doi.org/10.1016/j.msea.2014.03.135.
  40. Zhao, Y Y, Li D, Zhang Y S, “Effect of Welding Energy on Interface Zone of Al-Cu Ultrasonic Welded Joint”, Sci. Technol. Weld. Join., 2013, 18(4), p 354–360.
  41. Sarraf Z. S. A, “Investigation of the Crack Initiation in Designing of Ultrasonic Blade Horn Operating at 20 KHz Used for Cutting Processes,” in 2023 8th International Conference on Mathematics and Computers in Sciences and Industry (MCSI), Athens, Greece, 2023, pp. 145-149, doi: 10.1109/MCSI60294.2023.00031.
  42. Gu X, SuiC, Liu J, et al, “Microstructure and mechanical properties of Mg/Al joints welded by ultrasonic spot welding with Zn interlayer”. Mater Des 2019; 181: 108103.
DOI: https://doi.org/10.2478/jaes-2026-0012 | Journal eISSN: 2284-7197 | Journal ISSN: 2247-3769
Language: English
Page range: 91 - 100
Submitted on: Oct 30, 2026
Accepted on: Nov 16, 2026
Published on: May 21, 2026
In partnership with: Paradigm Publishing Services
Publication frequency: 2 issues per year

© 2026 Z. S. Al Sarraf, A. D. Younis, published by University of Oradea, Civil Engineering and Architecture Faculty
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.