Ultrasonic Welding Characteristics of Aluminum Alloy and PA6-GF40 Composites

Ultrasonic welding enables the bonding of materials with dissimilar thermal properties, making it a promising technology for industries requiring lightweight and high-strength components. This study investigates the effects of welding time on the joint characteristics of ultrasonic dissimilar material welding between 6000-series aluminum alloy and PA6-GF40 composite. In this study, tensile-shear tests were conducted to evaluate the changes in welding energy and joint strength under various welding time conditions. The joint cross-sections were observed using an optical microscope to assess joint quality and detect pore formation. The experimental results demonstrated that welding energy increased nonlinearly with welding time, and optimal joint strength was achieved under specific conditions. Additionally, optical microscopy revealed physical bonding and void formation at the interface between aluminum and PA6-GF40 composite. These findings provide insights into the relationship between welding time and joint strength, offering fundamental data for optimizing ultrasonic welding process parameters.