Microstructural characterization and mechanical properties of high power ultrasonic spot welded aluminum alloy AA6111–TiAl6V4 dissimilar joints

Aluminum alloy AA6111 and TiAl6V4 dissimilar alloys were successfully welded by high power ultrasonic spot welding. No visible intermetallic reaction layer was detected in as-welded AA6111/TiAl6V4 welds, even when transmission electron microscopy was used. The effects of welding time and natural aging on peak load and fracture energy were investigated. The peak load and fracture energy of welds increased with an increase in welding time and then reached a plateau. The lap shear strength (peak load) can reach the same level as that of similar Al–Al joints. After natural aging, the fracture mode of welds transferred from ductile fracture of the softened aluminum to interfacial failure due to the strength recovery of AA6111. •Dissimilar Al/Ti welds were produced by high power ultrasonic spot welding.•No visible intermetallic reaction layer was detected on weld interface.•The lap shear strength can reach the same level as that of similar Al–Al joints.•The fracture mode becomes interfacial failure after natural aging.