ISSN: 2277-3754

ISO 9001:2008 Certified

International Journal of Engineering and Innovative Technology (IJEIT)
Volume 4, Issue 5, November 2014

Analysis of Bonding Strength of Ultrasonic

Welding Process
Vijay Singh pal, Pavan Agrawal

Abstract: - In ultrasonic welding, high frequency vibrations

are combined with pressure to join two materials together
quickly and securely. Ultrasonic welding can join dissimilar
metals in a split second, ultrasonic welding eases problematic
assembly and this cost effective technique may be key to mass
producing fuel efficient. In this work effect of various
parameters on weld strength have been studied. Welding of .5
mm aluminium plates were successfully welded by 20 kHz
ultrasonic welding system. One dimensional vibration system
for ultrasonic lap spot welding of metal plate of aluminium
Fig 1 Ultrasonic metal welding
have studied .The relationships between weld strength and the
variables of weld energy, duration of weld cycle, have studied
Experiment was carried out to determine the mechanism of III. PARAMETER CONTROL
aluminium- aluminium plate bonding. These experiment, 1. Welding pressure or clamping pressure
including effect of amplitude and pat tern of bond formation. 2. Welding voltage
Experiment was carried to find out the optimum parameter for 3. Welding current
maximum strength. 4. Ultrasonic frequency
5. Welding time
6. Welding energy
I. INTRODUCTION 7. Constant amplitude
Ultrasonic welding is an industrial technique whereby 8. Weld location
two pieces of plastic or metal are joined together
seamlessly through high-frequency acoustic vibrations. IV. WELDING IN THE ENERGY MODE
One component to be welded is placed upon a fixed anvil, Welding in energy mode, i.e. with a constant energy
with the second component being placed on top. An setting, is known from ultrasonic plastics welding and can
extension ("horn") connected to a transducer is lowered also be used for ultrasonic metal welding. To achieve a
down onto the top component, and a very rapid (~20,000 constant quality the welding time is automatically
Hz), low-amplitude acoustic vibration is applied to a adjusted. Although this type of quality control is good
small welding zone. The acoustic energy is converted into with ultrasonic plastics welding, the approach has to be
heat energy by friction, and the parts are welded together more carefully applied when it comes to ultrasonic metal
in less than a second. welding.

II. ULTRASONIC METALS WELDING V. WELDING IN ENERGY MODE

The system that is used to scrub the pieces together Energy: 2000 ws
Weld location: at middle of lap
consists of four major components. The first of these is
Amplitude: 70%
the anvil. This is simply a piece of the machine, usually Pmax =300 w
with a replaceable head, that holds one of the components Sr. WELD TIME %Pmax T2*% strength(WEIGHT)
still while the other is rubbed against it. The "business NO. IN Pmax IN KG
end" of the ultrasonic system consists of three major SECONDS(T2)
parts. The first of these is the ultrasonic transducer. This
component takes an electrical signal from a power supply
that is providing a 20 khz AC signal and converts it to a 1 2.8 55 154.55 8.5
mechanical motion at the same frequency as shown in fig
1. The vibration that results is at a frequency that is 2 3.386 53 179.46 8.5
appreciably above the range of human hearing, hence the 3 4.86 40 194.4 9
name ultrasonic. There is a power supply which elevates
the frequency of the electrical current from the grid, then 4 3.2 62 198.4 9.5
the transducer that transforms electrical into mechanical
5 3.93 55 216.3 10
energy, then a booster that modifies the shape and
magnitude of vibrations an finally the horn that vibrates 6 3.64 62 225.8 11.5
the material to be welded, while it is clamped unto the Table 1 - weld time and strength in energy mode
stationary anvil.

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 4, Issue 5, November 2014
WELDING IN TIME MODE
TIME: 2.5 s
Weld location: at end edge of lap
Amplitude: 70%
Pmax =300w
Piece Weld %Pmax %Pmax*weld Strength(weight)
no energy. energy. In Kg
In WS
Fig 2. Relation between weld time and strength in energy
1 670 45 30150 6.5
mode
2 680 47 31960 6.5
3 720 46 33120 6.5
VI. WELDING IN THE TIME MODE 4 754.5 52 39308 9
This is the most suitable mode for ultrasonic metals 5 881 45 39645 9
welding. Welding energy and rate of compression are 6 816 50 40800 9
variable, but we only consider the variation in energy 7 850 50 42500 9.5
because rate of compression does minor effect on weld 8 964 51 49164 10
strength subject to the deviations of the work piece. They Table 3- weld energy and strength at 70% amplitude at end
should, however, stay within acceptable limits. The
welding process ends automatically as soon as the
nominal time value is achieved. The welding time is
defined as the duration of ultrasonic and can be both a
constant parameter and a variable parameter adjusted with
the help of quality control devices for an optimum weld.
Depending on the application the welding time can be
between 0.1 and approximately 4 seconds.
Fig 4. Relation between weld energy and strength at 70%
WELDING IN TIME MODE amplitude at end
TIME: 2.5 s
Weld location: at middle of lap VII. COMPARISON BETWEEN WELDING AT
Amplitude: 70% THE MIDDLE OF THE LAP AND AT THE EDGE
Pmax =300 w OF THE LAP
Piece Weld %Pmax %Pmax*weld Strength(weight) Front view
no energy. Energy. In Kg
In WS

1 912 33 30096 3
2 1043 39 40677 4
3 1281 64 81984 10
4 1450 57 82661 10
5 1451 60 87060 10
6 1345.8 71 95556 10.5
7 1655 60 99300 11
8 1845 55 101475 11
9 1708 68 116144 12.5 Top view
Table 2 weld energy and strength at 70% amplitude Fig 5 Welding at middle of lap
Front view

Top view
Fig. 3. Relation between weld energy and strength at 70%
Fig 6. Welding at end edge of lap
amplitude

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 4, Issue 5, November 2014
TIME: 2.5 s In this work, the controllable factors taken are Voltage
Amplitude: 70% (V), Current (I) and pressure (P). Since they affect
Pmax =300w strength and welding operation and these factors are
Sr. At the middle of the lap At the edge of the lap controllable in the ultrasonic welding process, they are
no considered as a controllable factor.
Energy (ws) Strength Energy Strength
(Kg) (ws) (Kg) B. Analysis of means and response graph for
1 912 3 670 6.5 strength
2 1043 4 680 6.5 Analysis of means
The analysis of each controllable factor is studied and the
3 1281 10 720 6.5
main effect of the same is obtained in table. Main effect
4 1450 10 754.5 9 of each factor at individual level i.e. at low, medium and
5 1451 10 881 9 high level is equal to the mean of strength of all
6 1345.8 10.5 816 9 experiments with the factor at individual level.
7 1655 11 850 9.5 (a) The main effect of voltage on strength at various level
calculated as follows
8 1845 11 964 10
L = (3.5+8.5+9)/3 =7.0 Kg
Table 4. Comparison between welding at the middle of the M = (10.5+6.5+8)/3 =8.33 Kg
lap and at the edge of the lap
H = (8.7+12.5+7.5)/3 =9.57 Kg
Table 4 shows that in case of welding at the edge of the
(b)The main effect of current on strength at various level
lap the bonding strength is much more compare to
calculated as follows
welding at the middle of the lap. It also consumes less
L = (3.5+10.5+8.7)/3 =7.57 Kg
energy and gives better strength. Because in case of
M = (8.5+6.5+12.5)/3 =9.17 Kg
welding at the edge of the lap the surrounding is mainly
H = (9+8+7.5)/3 = 8.17 Kg
air Which have low thermal conductivity compare to
(c) The main effect of pressure on strength at various
aluminum in case of welding at the middle of the lap.
level calculated as follows
Because of high thermal conductivity of aluminum, the
L = (3.5+6.5+7.5)/3 = 5.83 Kg
heat losses is more in case of welding at the middle of
M = (8.5+8+8.7)/3 = 8.4 Kg
the lap compare to in case of welding at the edge of the
H = (9+10.5+12.5)/3 =10.67 Kg
lap. So the welding at the edge is prefer than welding at
the middle.
Symbols Controllable
factors Strength (Kg)
VIII. EXPERIMENTATION AND DATA Low Medium High
COLLECTION V Voltage 7 8.33 9.57
Symbols Process Levels I Current 7.57 9.17 8.17
parameter Low Medium High P Pressure 5.83 8.4 10.67
V Voltage 230 340 450
(Volt)
Table 7 mean responses for strength
I Current 1.5 3.5 6.4
C. Response graph for means
(amp)
P Pressure .34 .43
The value obtained from the response table are plotted to
.52
(MPa) visualize the effect of three parameters. From the means
Table 5:-parameters and their levels of experiment response graph observation finding are illustrated as
follows-
A. Experimental results (a) Level III for voltage (V3) =9.57 Kg indicated as the
Experiment Voltage Current Pressure Strength optimum situation in terms of strength.
no. (v) (amp) (MPa) (Kg) (b) Level II for current (I2) =9.17 Kg indicated as the
optimum situation in terms of strength.
1 230 1.5 .34 3.5
(c) Level III for voltage (P3) =10.67 Kg indicated as the
2 230 3.5 .43 8.5
optimum situation in terms of strength.
3 230 6.4 .52 9 Main effect plot for Strength Data means
4 340 1.5 .52 10.5
5 340 3.5 .34 6.5
6 340 6.4 .43 8
7 450 1.5 .43 8.7
8 450 3.5 .52 12.5
9 450 6.4 .34 7.5 Fig 7.(a) Strength v/s Voltage
Table 6:- consolidated design of experiment table

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 4, Issue 5, November 2014
A. Comparison of result for maximum strength
Result Experimental Result from
result mathematical
modeling
Level V3-I2-P3 V3-I2-P3
Strength(Kg) 12.5 12.92
Table 9 - comparison of results

Fig 7.(b) Strength v/s Current

Fig 7.(c) Strength v/s pressure

Fig 7. Mean response graph for strength

Fig 8 comparison of results

D. Confirmation of experiment
XII. CONCLUSION
For maximum strength the combination of optimum
parameters (V3,I2,P3).It means high voltage, medium  The time mode is more favorable mode for ultrasonic
current and high pressure. For this combination V3=450 v metal welding.
, I2=3.5 amp and P3= .52 MPa ,the strength is 12.5 Kg.  Weld location should be considered in ultrasonic lap
joint welding, due to effect of thermal conductivity
X. MODELLING OF PARAMETERS of metals weld location also affect the welded
To generalize the result, the modeling of input quality. Welding at end edge of lap give comparative
parameters (Voltage, Current and Pressure) and output good welded quality and the more effectiveness of
parameters (Strength) is done using REGRESSION ultrasonic welding system.
MODELING and Matlab software R2011b. Now the
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ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 4, Issue 5, November 2014
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