ULTRASONIC WELDING

Bala Ganesh
18BPI0046
INTRODUCTION
Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are
locally applied to workpieces being held together under pressure to create a solid-state weld. It is
commonly used for plastics and metals, and especially for joining dissimilar materials. In ultrasonic
welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the
materials together. When applied to metals, a notable characteristic of this method is that the
temperature stays well below the melting point of the involved materials thus preventing any
unwanted properties which may arise from high temperature exposure of the materials.
Why to use US welding?
First - Ultrasonic assembly uses ultrasonic vibratory energy which is transmitted
throughthe parts to melt and bond thermoplastic materials And joining thin sheet gauge
metalsand other lightweight materials.

Second- This technique is fast, efficient, noron- contaminating and requires no

Third - In ultrasonic welding, there are noconnective bolts, nails, soldering materials, or
adhesives necessary to bind the materials.
PROCEDURE
For joining complex injection molded thermoplastic parts, ultrasonic welding equipment can be easily customized
to fit the exact specifications of the parts being welded. The parts are sandwiched between a fixed shaped nest
and a sonotrode connected to a transducer, and a ~20 kHz low-amplitude acoustic vibration is emitted. When
welding plastics, the interface of the two parts is specially designed to concentrate the melting process. One of the
materials usually has a spiked or rounded energy director which contacts the second plastic part. The ultrasonic
energy melts the point contact between the parts, creating a joint. This process is a good automated alternative
to glue, screws or snap-fit designs. It is typically used with small parts but it can be used on parts as large as a
small automotive instrument cluster. Ultrasonics can also be used to weld metals, but are typically limited to small
welds of thin, malleable metals, e.g. aluminum, copper, nickel. Ultrasonics would not be used in welding the
chassis of an automobile or in welding pieces of a bicycle together, due to the power levels required.
Ultrasonic welding of thermoplastics causes local melting of the plastic due to absorption of vibrational energy
along the joint to be welded. In metals, welding occurs due to high-pressure dispersion of surface oxides and local
motion of the materials. Although there is heating, it is not enough to melt the base materials.
Ultrasonic welding can be used for both hard and soft plastics, such as semicrystalline plastics, and metals.
The understanding of ultrasonic welding has increased with research and testing. The invention of more
sophisticated and inexpensive equipment and increased demand for plastic and electronic components has led
to a growing knowledge of the fundamental process. However, many aspects of ultrasonic welding still require
more study, such as relating weld quality to process parameters. Ultrasonic welding continues to be a rapidly
developing field.

Scientists from the Institute of Materials Science and Engineering (WKK) of University of Kaiserslautern, with
the support from the German Research Foundation have succeeded in proving that using ultrasonic welding
processes can lead to highly durable bonds between light metals and Carbon-fiber-reinforced polymer (CFRP)
sheets.

The benefits of ultrasonic welding are that it is much faster than conventional adhesives or solvents. The drying
time is very quick, and the pieces do not need to remain in a fixture for long periods of time waiting for the joint
to dry or cure. The welding can easily be automated, making clean and precise joints; the site of the weld is
very clean and rarely requires any touch-up work. The low thermal impact on the materials involved enables a
greater number of materials to be welded together.
ADVANTAGES
• Heat affected zone is minimized
• Very thin materials can be welded
• Surface deformation is minimum
• Welding of glass is also possible
• No defects due to gases, arc and filler metal
• Equipment is simple and moderate skill is enough
• Dissimilar materials can be joined
DISADVANTAGES
• Restricted to join thin materials
• Competitively not economical
• Material being welded may tend to weld to the tip and anvil
APPLICATIONS
• Manufacturing of toys
• Joining of electrical and electronic components
• Welding aluminium wire and sheet
• Mobiles, sports shoes, laminations, cars......
• Packing, medical industries, computers