Ultrasonic welding (UW), a most promising solid-state welding technique, is being developed for the automotive industry, more specifically, for joining components in electric vehicle batteries. It has also been used in rare-earth barium copper oxide (REBCO)-based superconductors, which have different stabilizing materials. At present, challenges remain when using UW to join aluminum (Al) and copper (Cu) in either application, and research in these areas are undeniably important for the future use of fully in-line UW applications. This paper provides a review of the current status of UW for joining Al and Cu, specifically in electric vehicle batteries and REBCO-based superconductors. Important issues about process characteristics and critical concerns about weld parameter optimization, joint structure morphology, temperature measurements, joint mechanical properties, and quality of the joints are addressed. Modeling and simulations using the finite element method in predicting the physical phenomena in the dynamic UW process are discussed. The status of electromechanical behaviors in ultrasonically welded joints in superconductors is detailed. Lastly, guidelines and valuable knowledge for the integration of Al and Cu UW in electric vehicle battery assembly and superconductors are provided as a basis for future research directions in these fields.

超声波焊接 (UW) 是一种最有前途的固态焊接技术，正在为汽车行业开发，更具体地说，用于连接电动汽车电池中的组件。它还被用于稀土钡铜氧化物 (REBCO) 基超导体，这些超导体具有不同的稳定材料。目前，在任一应用中使用 UW 连接铝 (Al) 和铜 (Cu) 时仍然存在挑战，而这些领域的研究对于未来完全在线 UW 应用的使用无疑具有重要意义。本文回顾了 UW 用于连接铝和铜的现状，特别是在电动汽车电池和基于 REBCO 的超导体中。关于工艺特性的重要问题和关于焊接参数优化、接头结构形态、温度测量的关键问题，接头的力学性能和接头的质量得到了解决。讨论了使用有限元方法来预测动态 UW 过程中的物理现象的建模和模拟。详细介绍了超导体中超声焊接接头的机电行为状况。最后，为电动汽车电池组件和超导体中 Al 和 Cu UW 的集成提供了指导和有价值的知识，作为这些领域未来研究方向的基础。