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Ulttrasonic metal welding


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  • 1. ULTRASONIC METAL WELDING A PRESENTATION ON SUBMITTED TO Dept. Of Mechanical Engg. Govt. Engg. College, Ajmer SUBMITTED BY Deepak Kumar Solanki 10ME20 GUIDED BY Respected BD Gidwani Sir & VK Verma Sir
  • 2. Ultrasonic Welding Lesson Objectives When you finish this lesson you will understand: • Ultrasonic Welding Definition, Characteristics, Process & Applications • Ultrasonic Power Generation • Interfacial Interactions & Dissimilar Metals Welding Learning Activities 1. View Slides; 2. Read Notes, 3. Listen to lecture 4. Do on-line workbook Keywords: Ultrasonic Welding, Transducer, Sonotrode, Anvil
  • 3. Ultrasonic Welding Process • Components of ultrasonic welding system include: – Transducer – Sonotrode – Anvil Anvil Mass Sonotrode tip Clamping force wedge Transducer Force WeldmentVibration
  • 4. • Clamping force • Welding time • Trigger Point • Frequency • Linear Vibration Amplitude • Welding Tools • Ultrasonic Power Ultrasonic Welding Variables
  • 5. 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
  • 6. AWS Welding Handbook
  • 7. • 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
  • 8. Source AWS handbook
  • 9. A W S W elding H andbook
  • 10. A W S W elding H andbook
  • 11. 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
  • 12. • 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
  • 13. Source AWS handbook Ultrasonic Welding Materials Combinations
  • 14. Extreme Interpenetration Nickel Foil (top) to Gold-Plated Kovar Foil Local Plastic Flow Dark Regions are Trapped Oxide Nickel Foil (top) to Molybdenum Sheet Very Little Penetration, Thin Bond Line, Fiber Flow Molybdenum Sheet to Itself AWS Welding Handbook
  • 15. AWS Welding Handbook Comparison With Resistance Spot Weld
  • 16. • 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
  • 17. • 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
  • 18. 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
  • 19. • 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