Microstructure and Mechanical Properties of Titanium and Copper Dissimilar Joints Fabricated by Ultrasonic Spot Welding

SHI Chenxu; WANG Shiqing; QIANG Wei; LI Changlin; ZHANG Qiang

doi:10.3969/j.issn.1674-6457.2026.08.004

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (8) : 53-62. DOI: 10.3969/j.issn.1674-6457.2026.08.004

Key Technologies for Precision Forming of High-end Energy and Aerospace Equipment Components

Microstructure and Mechanical Properties of Titanium and Copper Dissimilar Joints Fabricated by Ultrasonic Spot Welding

SHI Chenxu¹, WANG Shiqing^1,*, QIANG Wei¹, LI Changlin¹, ZHANG Qiang²

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Abstract

The work aims to systematically investigate the mechanism of ultrasonic spot welding process parameters and Ag foil interlayer on inhibiting the formation of brittle phases, to provide a reliable theoretical basis and feasible engineering application scheme for the high-quality and high-efficiency joining of Ti/Cu dissimilar metals. Ultrasonic spot welding technology was adopted to systematically explore the effect law of welding pressure, vibration amplitude and Ag foil interlayer thickness on the microstructure and mechanical properties of the joints, and reveal the interfacial regulation mechanism of the Ag foil interlayer. The Ag foil interlayer could effectively block the direct contact between Ti and Cu atoms, inhibit the formation of brittle phases such as TiCu and Ti₂Cu, and form a gradient transition layer of Ag-Cu infinite solid solution and Ag-Ti limited solid solution at the interface. The hardness distribution of the joint presented an asymmetric characteristic with a gradient increase from the copper side to the titanium side. The shear strength of the joint increased with the increase of each welding process parameter. Under the optimized process parameters of welding pressure 0.4 MPa, vibration amplitude 40 μm and 100 μm Ag foil interlayer, the maximum shear strength of the joint reached 138.59 MPa, which was 29.8% higher than that of the joint with 50 μm Ag foil interlayer. Ultrasonic spot welding can realize high-quality solid-state joining of TC4 titanium alloy and H62 brass alloy. The Ag foil interlayer can effectively regulate the interfacial microstructure and improve the joint performance, which provides support for the engineering application of this joining system.

Key words

TC4 titanium alloy / H62 copper alloy / ultrasonic spot welding / silver foil interlayer / welding process parameters / microstructure / mechanical properties

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SHI Chenxu, WANG Shiqing, QIANG Wei, LI Changlin, ZHANG Qiang. Microstructure and Mechanical Properties of Titanium and Copper Dissimilar Joints Fabricated by Ultrasonic Spot Welding[J]. Journal of Netshape Forming Engineering. 2026, 18(8): 53-62 https://doi.org/10.3969/j.issn.1674-6457.2026.08.004

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