Research Progress and Development Trends of Ultrasonic-assisted Joining Technology for Magnesium and Aluminum Alloys

DU Wenyu; WANG Yan; ZHOU Yisong; XIE Xufeng; ZHONG Tao; HU Hongjun

doi:10.3969/j.issn.1674-6457.2025.09.004

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 45-59. DOI: 10.3969/j.issn.1674-6457.2025.09.004

Light Alloy Forming

Research Progress and Development Trends of Ultrasonic-assisted Joining Technology for Magnesium and Aluminum Alloys

DU Wenyu¹, WANG Yan¹, ZHOU Yisong¹, XIE Xufeng¹, ZHONG Tao^2,*, HU Hongjun^1,*

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Abstract

The work systematically reviews research advances and development trends in ultrasonic-assisted joining of magnesium/aluminum (Mg/Al) dissimilar materials through analysis of seven key techniques: Ultrasonic Spot Welding (USW), Ultrasonic-assisted Transient Liquid Phase bonding (U-TLP), Ultrasonic-assisted Friction Stir Welding (UAFSW), Ultrasonic Vibration-assisted Arc Welding (UAW), Ultrasonic-assisted Brazing, Ultrasonic-assisted Riveting, and Ultrasonic Adhesive Bonding: demonstrates that ultrasonic vibration enhances joint quality through multiple mechanisms: including improved material plasticity, suppressed formation of brittle intermetallic compounds (IMCs), enhanced interfacial mechanical interlocking, refined grain structure, and disrupted surface oxides. Critical parameters decisively govern interfacial IMC characteristics: welding energy (e.g., about 1 000 J for peak strength in USW), interlayer design (e.g., Zn/Ag foils inhibiting Al₁₂Mg₁₇), and ultrasonic parameters (amplitude, frequency, duration). Ultrasonic promotion of plastic deformation and elemental diffusion markedly optimizes mechanical properties; U-TLP joints achieve shear strengths up to 95.3 MPa with extended fatigue life. Persistent challenges include inadequate parameter optimization, limited interfacial stability, insufficient dynamic performance data (e.g., corrosion, high temperature), and industrial-scale bottlenecks. Future priorities should involve elucidating ultrasonic-thermal-stress coupling mechanisms, developing intelligent process control systems, and expanding aerospace/automotive lightweight applications.

Key words

Mg/Al alloys / ultrasonic-assisted joining / friction stir welding / ultrasonic spot welding / welding

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DU Wenyu, WANG Yan, ZHOU Yisong, XIE Xufeng, ZHONG Tao, HU Hongjun. Research Progress and Development Trends of Ultrasonic-assisted Joining Technology for Magnesium and Aluminum Alloys[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 45-59 https://doi.org/10.3969/j.issn.1674-6457.2025.09.004

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Funding

The Chongqing Natural Science Foundation Project (CSTB2023NSCQ-MSX0079); The Open Fund of the State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University (82315001); Graduate Innovation Project of Chongqing University of Technology (gzlcx20252028)