Research on Microstructure and Properties of Ultrasonic Welded Large-Diameter Aluminum Wire/Cu (Ni-Plated Copper) Terminal Joints

In this study, the microstructure and mechanical properties of ultrasonic welded joints between large-diameter aluminum wire and Cu (Ni-plated copper) terminals were systematically investigated, to reveal the underlying fracture mechanisms. The cross-sectional morphology, interfacial microstructure, and mechanical properties of the two types of welded joints are investigated. The results indicate that ultrasonic welding produces well-structured Al-Cu and Al-Ni joints. Under the same welding proc