Friction and plastic flow at the bond interface are believed to be the most fundamental phenomena in ultrasonic consolidation. This paper focuses on friction’s contribution to bonding mechanism in ultrasonic welding. Based on a 3-D thermo-mechanical dynamic FEM model, the distributions of temperature and plastic deformation caused by the friction stress are presented. Temperature and plastic deformation are found to vary with vibration cycles. A saturation phenomenon is identified that after certain number of vibration cycles, the plastic deformation at the bond interface reaches a “steady-state”.

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