Ultrasonic Metal Welding in Advanced Manufacturing

This book presents a systematic review and in-depth analysis of global research advancements in ultrasonic metal welding within the field of advanced manufacturing over the past fifteen years. By utilizing a consistent five-dimension methodology, it uncovers universal principles and material-specific phenomena, directly translating fundamental science into actionable solutions for joining dissimilar pairs (e.g., Mg/Steel, Al/Cu).The monograph is distinguished by its broad material coverage, comprehensive organization, and unified analytical approach. It begins with ultrasonic metal welding systems, process characteristics, and key variables, such as welding energy, frequency, power, vibration amplitude, pressure, and interfacial temperature. It then systematically examines similar and dissimilar joining in aluminum alloys, magnesium alloys, copper alloys, and materials associated with NiTi alloys. Representative material combinations include Al/Steel, Al/Mg, Al/Ti, Mg/Cu, Mg/steel, Cu/Al, Cu/Ni, Ni/Al, and Ni/Ti. Each material system is discussed within the same framework comprising five aspects: microstructure, microhardness, interfacial temperature, joint performance, and joining mechanism. This structure supports meaningful comparison among material combinations while clearly presenting their specific differences in dynamic recrystallization, plastic flow, mechanical interlocking, and the formation of intermetallic compounds. It therefore strengthens the coherence and systematic character of the book.A further advantage of the monograph is its close integration of fundamental mechanism analysis with engineering needs. Evidence from microstructural characterization, temperature measurement, mechanical testing, and studies of process parameters is synthesized to explain changes in joint performance through microstructural evolution and to establish joining mechanisms and relationships for parameter control, rather than merely presenting isolated experimental observations. The discussions of interlayers, surface coatings, material stacking sequences, and sonotrode design help readers to understand the applicable conditions and optimization routes for different material systems. At the same time, the book provides a balanced assessment of current limitations involving component size, material thickness, equipment power, and process monitoring. On this basis, it also outlines future research directions. Combining scientific rigor, readability, and engineering relevance, the book offers a systematic reference for teaching and research, process design, and quality control in materials science, welding engineering, and mechanical engineering.