本研究的目標是進行鋁合金/熱塑性碳纖複材之異質超音波銲接的研發，內容包含超音波刀具設計與製作、鋁合金同質超音波銲接製程開發、鋁合金/碳纖複材之異質超音波銲接製程開發。對於刀具開發，首先依據銲接需求進行超音波刀具設計，銲頭為10×10 mm的菱形咬花平面；接著，透過有限元素分析對超音波刀具進行模態分析及簡諧分析，模擬刀具的共振頻率及振幅；完成刀具製作後，使用雷射位移感測計進行共振頻率量測與驗證。對於鋁合金同質製程開發，首先進行鋁合金6061-O超音波銲接製程研發，利用剪力拉伸試驗與金相顯微分析，了解三個主要製程參數(能量、下壓力及振幅)與銲點品質間的關係。再使用中央複合設計試驗(CCC)進行參數分析與最佳化，其最佳參數組合為能量3113 J、下壓力768 N、振幅100%。對於鋁合金/碳纖複材製程開發，先以前述成果為基礎，分析三個主要參數對銲點品質的影響程度，再運用試片表面處理技術提升銲點品質，其較佳參數組合為能量1400 J、下壓力120 N、振幅100%、鋁合金表面酸洗。 The objective of this study is to develop the dissimilar ultrasonic welding (UW) process for aluminum alloy (Al) and thermoplastic carbon fiber reinforced plastic (TP-CFRP) sheets. The main contents include the design and manufacturing of UW tools, development of Al/Al similar UW process, and development of Al/CFRP dissimilar UW process. For tool development, a UW tool with 10×10 mm diamond-shaped surface texture was designed based on the welding requirements. Next, the modal analysis and harmonic analysis of the UW tool were conducted by the finite element analyses to estimate the harmonic frequency and amplitude of the designed tool. After tool manufacturing, the harmonic frequency and amplitude of the UW tool were obtained and validated by the laser displacement sensor. For Al/Al similar UW process, Al 6061-O sheets were used to understand the relations between three important processing parameters, welding energy, punching force and amplitude, and welding qualities. Then, the parameter analysis and optimization were carried out by the central composite circumscribed (CCC) design tests. The optimal processing parameters were the energy of 3113 J, force of 768 N and amplitude of 100%. For Al/CFRP dissimilar UW process, the previous results were first taken as a reference. The effects of three processing parameters on the welding quality were then studied. Then the welding quality was further improved by surface treatment technology. The good processing parameters were the energy of 1400 J, force of 120 N, amplitude of 100%, and nitric acid surface cleaning.