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Ultrasonic Welding PDF

This document provides an overview of ultrasonic welding, including definitions, characteristics of the process, power generation methods, interfacial interactions, materials combinations, advantages, limitations, and applications. Some key points: - Ultrasonic welding is a solid state welding process that uses high-frequency vibratory energy to produce coalescence between faying surfaces under low static pressure. - It can be used to weld thin sections and materials like plastics that cannot be welded through other processes. Limitations include part thickness and inability to make cut welds. - The process involves applying an oscillating force from a sonotrode to the interface between parts under a static clamping force. This produces deformation

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914 views43 pages

Ultrasonic Welding PDF

This document provides an overview of ultrasonic welding, including definitions, characteristics of the process, power generation methods, interfacial interactions, materials combinations, advantages, limitations, and applications. Some key points: - Ultrasonic welding is a solid state welding process that uses high-frequency vibratory energy to produce coalescence between faying surfaces under low static pressure. - It can be used to weld thin sections and materials like plastics that cannot be welded through other processes. Limitations include part thickness and inability to make cut welds. - The process involves applying an oscillating force from a sonotrode to the interface between parts under a static clamping force. This produces deformation

Uploaded by

sanmite
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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ULTRASONIC WELDING

Ultrasonic Welding
Lesson Objectives When you finish this lesson you will understand: Ultrasonic Welding Definition, Characteristics, Process & Applications Ultrasonic Power Generation Interfacial Interactions & Dissi ilar !etals Welding Learning Activities "# $iew %lides& '# (ead )otes, *# +isten to lecture ,# Do on-line wor./oo.

Ke !ords" Ultrasonic Welding, 0ransducer, %onotrode, An1il

E le c tr ic a l

S o lid S ta te W e ld in g

C h e m ic a l
F r ic tio n
M e c h a n ic a l

P re s s u re

U lt r o s o n ic W e ld

Definition of Ultrasonic Welding


A solid state welding process in which coalescence is produced at the faying surfaces /y the application of high fre2uency 1i/ratory energy while the wor. pieces are held together under oderately low static pressure#

Ultrasonic Welding Process


Cla ping force

Process Description: Co ponents of %onotrode ultrasonic welding tip syste include: $ibration
3 0ransducer 3 %onotrode 3 An1il

#ass

wedge 0ransducer

Weld ent Anvil 4orce

Ultrasonic Welding !echanis


Cla ping force

A static cla ping force is applied perpendicular to the interface /etween the wor. pieces# 0he contacting sonotrode oscillates parallel to the interface# Co /ined effect of static and oscillating force produces defor ation which pro otes %&'() K*+ welding#

#ass

wedge 0ransducer %onotrode tip wor.piece Anvil 4orce

,rocess $ariations
S-ot Welding Ring Welding Line Welding ' Linear Sonotrode Contin.o.s Sea/ Welding ' Roller Sonotrode #icro/iniat.re Welding

T -ical %)&& .ltrasonic s-ot't -e !elding /ac0ine


Courtesy AW% hand/oo.

AWS Welding *andboo1

%&& W Lateral Drive Ultrasonic Welder

AWS Welding *andboo1

T -ical Ring Welding A--lications


Ti- in S0a-e o2 Weld
AWS Welding *andboo1

Attac0/ent 2or Contin.o.s Ring Welding

AWS Welding *andboo1

0ip

Traversing *ead 2or Contin.o.s Sea/ Welding


AWS Welding *andboo1

Welding $ariables

Ultrasonic Welding $aria/les


Ultrasonic power Cla ping force Welding ti e 4re2uency +inear $i/ration A plitude

Ultrasonic Welding Power Generation


5lectrical power of 67 89 is supplied to the fre2uency con1erter# 0he fre2uency con1erter con1erts the re2uired 67 89 signal to the welding fre2uency :fro "7 to ;< .89=#
Electrical energ

,o!er Generation

3re4.enc converter

Transd.cer
$ibrator transd.cer

AWS Welding *andboo1

4re2uency is transfor ed to 1i/ration energy through the transducer# 5nergy re2uire ent esta/lished through the following e pirical relationship#
3 3 3 3 5 > ? :80=*@' 5 > electrical energy 8 > $ic.ers hardness nu /er 0 > thic.ness of the sheet

Ultrasonic Welding Power Generation


Electrical energ

,o!er Generation

3re4.enc Converter

$ibrator transd.cer

,o!er Re4.ire/ents

E = K(HT )

3/2

W0ere" E 5 electrical energ 6 W7s 89: 1 5 a constant 2or a given !elding s ste/ * 5 $ic1ers 0ardness n./ber o2 t0e s0eet T 5 t0ic1ness o2 t0e s0eet in contact !it0 t0e sonotrode ti-6 in; 8//:
T0e constant <K= is a co/-le> 2.nction t0at a--ears to involve -ri/aril t0e electro/ec0anical conversion e22icienc o2 t0e transd.cer6 t0e i/-edance /atc0 into t0e !eld6 and ot0er c0aracteristics o2 t0e !elding s ste/; Di22erent t -es o2 transd.cer s ste/s 0ave s.bstantiall di22erent K val.es;

%ource AW% hand/oo.

AWS Welding *andboo1

AWS Welding *andboo1

Sonotrode Ti- and Anvil #aterial


*ig0 S-eed Tool Steels Used to Weld So2t #aterials Al./in./ Co--er Iron Lo! Carbon Steel *ardenable Nic1el'?ase Allo s Used to Weld *ard6 *ig0 Strengt0 #etals and Allo s

Ultrasonic Welding Interfacial Interaction


+ocali9ed te perature rises resulting fro interfacial slip and plastic defor ation# 0e perature is also influenced /y power, cla ping force, and ther al properties of the aterial# +ocali9ed Plastic Defor ation !etallurgical pheno ena such as recrystalli9ing, phase transfor ation, etc##### can occur#

Ultrasonic Welding !aterials Co /inations

%ource AW% hand/oo.

E>tre/e Inter-enetration
Nic1el 3oil 8to-: to Gold',lated Kovar 3oil

Local ,lastic 3lo! Dar1 Regions are Tra--ed O>ide


Nic1el 3oil 8to-: to #ol bden./ S0eet

$er Little ,enetration6 T0in ?ond Line6 3iber 3lo!


#ol bden./ S0eet to Itsel2

AWS Welding *andboo1

Co/-arison Wit0 Resistance S-ot Weld

AWS Welding *andboo1

Ad1antages of Ultrasonic Welding


)o heat is applied and no elting occurs# Per its welding of thin to thic. sections# Welding can /e ade through so e surface coatings# Pressures used are lower, welding ti es are shorter, and the thic.ness of defor ed regions are thinner than for cold welding#

+i itations of Ultrasonic Welding


0he thic.ness of the co ponent adAacent to the sonotrode tip ust not eBceed relati1ely thin gages /ecause of power li itations of the e2uip ent# Process is li ited to lap Aoints# Cutt welds can not /e ade /ecause there is no eans of supporting the wor.pieces and applying cla ping force#

Ot0er ,rocess $ariations Ultrasonic Welding o2 Non'/etallic Ultrasonic ,lastic Welding

Welds Can ?e #ade to Non'#etallic S.bstrate #aterials Coated !it0 T0in La ers o2 #etal 3il/s
#aterial Welded #etal 3il/ Non'#etallic

AWS Welding *andboo1

Ultrasonic Welding of Plastics


Ad1antages
3 4ast 3 Can spot or sea weld

+i itations
3 52uip ent co pleB, any 1aria/les 3 Dnly use on s all parts 3 Cannot weld all plastics

0.1.1.2.5.T25.95.12

Applications of Ultrasonic Welding


Asse /ling of electronic co ponents such as diodes and se iconductors with su/strates# 5lectrical connections to current carrying de1ices including otors, field coils, and capacitors# 5ncapsulation and pac.aging# Plastic parts

AWS Welding *andboo1

Note !eld -rogression 8no !eld in center:

AWS Welding *andboo1

%tarter otor ar ature with wires Aoined in co utator slots /y ultrasonic welding Ultrasonically welded 8elicopter access door# Courtesy AW% hand/oo.

4ield coil asse /led /y ultrasonic welding


Courtesy AW% hand/oo.

AWS Welding *andboo1

Wire ?.ndle ,laced in 9a!s

Ultrasonic T ing Tool


#etal Ta-e 3ed Aro.nd b.ndle o2 Wires and !elded once6 t0en c.t and !elded again;

Ultrasonic *orn ?.ndled Wires

Welds

3irst Weld #ade

C.t and Second Weld #ade

Ultrasonic Stitc0 8Clad: Welding


Sonatrode

Anvil

Lo.1s6 et al <Ultrasonic ?onding #et0od= US ,atenet @6&AA6@(& A.g; B6 C&&&

Ultrasonic Welding o2 Eraser *older on ,lastic ,encil

Coinon6 A6 Trajber6 D6 <,encil *aving and Eraser'*olding 3err.le Sec.red b Ultrasonic Welding= US ,atent )6((E6AF% 9.l (6 %AAB

E>-losive Gas Generator 3or A.to Air ?ag


8,lastic Ultrasonic Weld: Gas Generating E>-losive ,o!der ,ri/er ,lastic CaWelded to ,lastic ?ase Ultrasonic Weld

Avor 6 et al <Electrical Initiator= US ,atent )6(@F6B%E 9.ne A6 %AAB;

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