{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,10,17]],"date-time":"2026-10-17T17:49:17Z","timestamp":1792259357271,"version":"4.4.0"},"reference-count":18,"publisher":"Springer Science and Business Media LLC","issue":"1","license":[{"start":{"date-parts":[[2025,7,1]],"date-time":"2025-07-01T00:00:00Z","timestamp":1751328000000},"content-version":"tdm","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0"},{"start":{"date-parts":[[2025,7,1]],"date-time":"2025-07-01T00:00:00Z","timestamp":1751328000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0"}],"content-domain":{"domain":["link.springer.com"],"crossmark-restriction":false},"short-container-title":["Sci Rep"],"abstract":"<jats:title>Abstract<\/jats:title>\n          <jats:p>The presence of intermetallic compounds (IMC) can significantly degrade the mechanical properties of joints, leading to premature failure. This paper presents a detailed investigation into the mechanical manufacturing and forming quality of ultrasonically welded joints between aluminum wire, copper terminals and nickel-coated copper terminals. The electroplated nickel coating enhances the corrosion resistance and operating temperature tolerance of copper substrate. The changes in failure load and energy absorption of welded joints were analyzed by examining the force-displacement curves. Microscopic morphology and elemental composition of joints were studied using scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS). The nickel-coated copper terminals inhibit metallurgical bonding to some extent and reduce the formation of IMCs at the weld interface. The average failure load of the Al-Ni joint was 2558.85\u00a0N which is 2.05% lower than Al-Cu joint, which had an average failure load of 2612.52\u00a0N. The average energy absorption of the Ni joints (21.65\u00a0J) was 20.14% lower than Al-Cu joints (27.11\u00a0J). The results indicate that while the coating has a negligible effect on joint strength, it does weaken the impact and seismic resistance of the joint. The joints can be used in manufacturing electrical components such as connectors, switches and sensors, where reliable electrical conductivity and resistance to corrosion are critical.<\/jats:p>","DOI":"10.1038\/s41598-025-08477-2","type":"journal-article","created":{"date-parts":[[2025,7,1]],"date-time":"2025-07-01T21:59:14Z","timestamp":1751407154000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":7,"title":["Investigation of joint formation in aluminum wire and nickel-coated copper terminals using ultrasonic welding"],"prefix":"10.1038","volume":"15","author":[{"given":"Haohan","family":"Zhang","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Lun","family":"Zhao","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Zeshan","family":"Abbas","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Wanlu","family":"Hong","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2025,7,1]]},"reference":[{"key":"8477_CR1","doi-asserted-by":"crossref","unstructured":"Tsujino, J., Ihara, S., Harada, Y., Kasahara, K. & Sakamaki, N. Characteristics of coated copper wire specimens using high frequency ultrasonic complex vibration welding equipments. In Ultrasonics 42 121\u2013124 (2004).","DOI":"10.1016\/j.ultras.2004.01.051"},{"key":"8477_CR2","doi-asserted-by":"publisher","first-page":"117294","DOI":"10.1016\/j.jmatprotec.2021.117294","volume":"298","author":"C Luo","year":"2021","unstructured":"Luo, C. & Zhang, Y. Joining of copper foils via al\/ni reactive multilayer nanofoils. J. Mater. Process. Technol. 298, 117294 (2021).","journal-title":"J. Mater. Process. Technol."},{"key":"8477_CR3","doi-asserted-by":"crossref","unstructured":"Abbas, Z., Zhao, L., Deng, J., Wang, S. & Hong, W. Advances in ultrasonic welding of lightweight alloys: A review. High Temp. Mater. Process 42 (2023).","DOI":"10.1515\/htmp-2022-0298"},{"key":"8477_CR4","doi-asserted-by":"publisher","DOI":"10.1007\/s40194-023-01589-1","author":"Z Lun","year":"2023","unstructured":"Lun, Z., Shicheng, W., Jiguang, L., Abbas, Z. & Gang, X. Performance enhancement of clinched joints with ultrasonic welding for similar and dissimilar sheet metals. Weld. World. https:\/\/doi.org\/10.1007\/s40194-023-01589-1 (2023).","journal-title":"Weld. World"},{"key":"8477_CR5","doi-asserted-by":"publisher","first-page":"133015","DOI":"10.1016\/j.matlet.2022.133015","volume":"327","author":"F Ye","year":"2022","unstructured":"Ye, F., Lu, H. & Qi, H. Joints formation and bonding mechanism of ultrasonic welded multi-strand single core copper cables with copper terminals. Mater. Lett. 327, 133015 (2022).","journal-title":"Mater. Lett."},{"key":"8477_CR6","doi-asserted-by":"publisher","first-page":"1","DOI":"10.1016\/j.jmapro.2022.04.007","volume":"78","author":"H Lu","year":"2022","unstructured":"Lu, H., Ye, F. & Wang, Y. Orthogonal experiments and bonding analysis of ultrasonic welded multi-strand single core copper cables. J. Manuf. Process. 78, 1\u201310 (2022).","journal-title":"J. Manuf. 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