Advances in ultrasonic welding of lightweight alloys: A review

Abstract The lightweight alloy sheet materials have been widely used in industries such as automobiles, aviation, and aerospace. However, there are huge challenges in the structural joining process. Likewise, industries are probing new technologies and are rapidly adapting to more complex light alloy materials. The ultrasonic metal welding is a reliable solid-phase joining technology, which has incomparable development prospects in the high-strength joining of lightweight alloy sheet materials. This article summarizes the research progress of ultrasonic welding of aluminum alloy, magnesium alloy, and titanium alloy thin plates in recent years. The key features of this review article are the ultrasonic welding process, advantages, applications, and limitations. It introduces the welding process parameters to explore the breakthroughs for straightforward direction. Furthermore, to strengthen the phenomena, the current state of the ultrasonic welding of lightweight alloys and their future perspectives are also reflected.