Abstract
The thermo-mechanical analysis of an ultrasonic spot welding process was performed using developed finite element models. Temperature–time histories of aluminium specimens during welding were successfully obtained from the analysis and validated by physical tests. It was shown that the effect of frictional heating on the plastic deformation of aluminium during ultrasonic spot welding was significant and should be included in the analysis of the welding process in order to achieve good correlation with the physical phenomenon.
