Research progress of aluminum and magnesium ultrasonic welding

As light metals, aluminum and magnesium have been widely used in automotive manufacturing, but the welding of Al/Mg joints is facing challenges. However, it is difficult to obtain high-quality aluminum/magnesium joints with traditional arc welding methods. As a solid-phase welding technology, ultrasonic metal welding has the characteristics of high welding efficiency and less welded defects. It is also suitable for welding sound metal bonds. Aluminum and magnesium ultrasonic welding has become a research hotspot. Therefore, the evolution of microstructures and mechanical performance of Al/Mg and multi-layer Al/Mg ultrasonic welding, and the new study works, including the molecular dynamic simulation of Al/Mg ultrasonic welding and hybrid based on ultrasonic welding are summarized. Furthermore, several promising research directions are proposed to guide in-depth investigations into the ultrasonic welding of Al/Mg dissimilar joints.