Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

@article{186944,
        author = {RETHISH G},
        title = {A Literature Review on Ultrasonic Metal Welding for Dissimilar Materials},
        journal = {International Journal of Innovative Research in Technology},
        year = {2025},
        volume = {12},
        number = {6},
        pages = {3758-3760},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=186944},
        abstract = {Ultrasonic Metal Welding (USMW) has emerged as a highly efficient solid-state joining technique for bonding similar and dissimilar lightweight metallic materials. The process is widely adopted in automotive, aerospace, and battery manufacturing sectors due to its low heat input, clean joint formation, and suitability for thin foils. This report reviews recent developments in USMW, focusing on interfacial bonding mechanisms, modelling approaches, surface engineering, quality monitoring, and industrial applications. A hybrid literature review approach is adopted, combining both thematic evaluation and key contributions of individual studies. The review highlights the influence of process parameters, surface conditions, sonotrode design, and real-time monitoring on weld quality. Furthermore, current challenges, research gaps, and future prospects for advanced industrial implementation are discussed.},
        keywords = {USM welding, Ultrasonic Metal Welding, solid-state welding, process parameters, dissimilar joining.},
        month = {November},
        }