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ULTRASONIC METAL WELDING
APRESENTATION
ON
SUBMITTED TODept. Of Mechanical Engg.Govt. Engg. College, Ajmer
SUBMITTED BYDeepak Kumar Solanki10ME20
GUIDED BYRespectedBD Gidwani Sir &VK Verma Sir
Ultrasonic Welding
Lesson ObjectivesWhen you finish this lesson you will understand:• Ultrasonic Welding Definition, Characteristics, Process & Applications• Ultrasonic Power Generation• Interfacial Interactions & Dissimilar Metals Welding
Learning Activities1. View Slides; 2. Read Notes, 3. Listen to lecture4. Do on-line
workbook
Keywords: Ultrasonic Welding, Transducer, Sonotrode, Anvil
Ultrasonic Welding Process
• Components of ultrasonic welding system include:– Transducer– Sonotrode– Anvil Anvil
Mass
Sonotrode tip
Clampingforce
wedge Transducer
Force
WeldmentVibration
• Clamping force• Welding time • Trigger Point• Frequency • Linear Vibration Amplitude• Welding Tools• Ultrasonic Power
Ultrasonic Welding Variables
Ultrasonic Welding Power Generation
• Electrical power of 60 Hz is supplied to the frequency converter.
• The frequency converter converts the required 60 Hz signal to the welding frequency (from 10 to 75 kHz).
Electrical energy
Frequency converter
Vibratory transducer
Transducer
AWS Welding Handbook
• Frequency is transformed to vibration energy through the transducer.
• Energy requirement established through the following empirical relationship.– E = K (HT)3/2
– E = electrical energy, W*s (J)
– H = Vickers hardness number
– T = thickness of the sheet
Electrical energy
Frequency Converter
Vibratory transducer
Ultrasonic Welding Power Generation
Source AWS handbook
AWS Welding Handbook
AWS Welding Handbook
Sonotrode Tip and Anvil Material
High Speed Tool Steels used to weld• Soft Materials• Aluminum• Copper• Iron• Low Carbon Steel
Hardenable Nickel-Base Alloys used to weld• Hard, High Strength Metals and Alloys
• Localized temperature rises resulting from interfacial slip and plastic deformation.
• Temperature is also influenced by power, clamping force, and thermal properties of the material.
• Localized Plastic Deformation• Metallurgical phenomena such as
recrystallizing, phase transformation, etc. can occur.
Ultrasonic Welding Interfacial Interaction
Source AWS handbook
Ultrasonic Welding Materials Combinations
Extreme InterpenetrationNickel Foil (top) to Gold-Plated Kovar Foil
Local Plastic FlowDark Regions are Trapped OxideNickel Foil (top) to Molybdenum Sheet
Very Little Penetration, Thin Bond Line, Fiber FlowMolybdenum Sheet to Itself
AWS Welding Handbook
AWS Welding HandbookComparison With Resistance Spot Weld
• No heat is applied and no melting occurs• Permits welding of thin to thick sections• Welding can be made through some surface
coatings• Dissimilar metals having vastly different
melting points can be joined• Pressures used are lower, welding times are
shorter, and the thickness of deformed regions are thinner than for cold welding
Advantages of Ultrasonic Welding
• The thickness of the component adjacent to the sonotrode tip is restricted because of power limitations of the equipment.
• Process is limited to lap joints.• Butt welds can not be made because there is no
means of supporting the work pieces and applying clamping force.
• Due to fatigue loading the life of equipment is short.
Limitations of Ultrasonic Welding
Ultrasonic Welding of Plastics
• Advantages– Fast– Can spot or seam weld
• Limitations– Equipment complex,
many variables– Only use on small parts– Cannot weld all plastics
0.1.1.2.5.T25.95.12
• Assembling of electronic components such as diodes and semiconductors with substrates
• Electrical connections to current carrying devices including motors, field coils, and capacitors
• Encapsulation and packaging• Plastic parts• Fabricating nuclear fuel elements• In aircraft structural applications.
Applications of Ultrasonic Welding