One of the welding processes that used in Engineering field is the ultrasonic welding. Thanks for the colleagues who give this slides to publish.

1. ULTRASONIC
WELDING

2. What is Ultrasonic welding ?
•Ultrasonic metal welding is a technique suitable
for joining both similar and dissimilar metal work
pieces or welding a piece of metal to a metallized
substrate (ceramics or glass).
•The weld formation is caused by the application of
external pressure and ultrasonic vibrations.

3. Equipment's for ultrasonic
welding
Ultrasonic metal welding equipment consists
of 3 fundamental parts
1.The electrical part
2.The electromechanical transducer
3.The mechanical part

4. 1.The electrical part
a. a generator, producing an electrical
signal (in general a sine wave), being the
input signal for the amplifier
b. a timing circuit, by which the required
welding time can be preset
c. an automatic frequency adjustment
system, in order to maintain resonance
conditions during the welding operation d.
an amplifier, able to supply sufficient
electrical power

5. The electromechanical
transducer
• This transducer converts the electrical
power into mechanical vibrations.
• The transducer can be either of the
magnetostrictive or the piezo-electric type.
• The transducer is coupled to the
waveguide system.

6. 2.The mechanical part
a) a waveguide system with an amplitude transformer. This
system guides the mechanical vibration from the transducer
to the work piece
b) a welding tool or welding tip contracting the upper work
piece. The welding tool is situated at one end of the
waveguide system
c) an anvil. The work pieces to be welded are clamped between
the welding tool and the anvil
d) a mechanical frame, on to which all parts are mounted. This
includes a mechanism to clamp the work pieces between
welding tool and anvil.

7. a)Components of an ultrasonic welding machine for making lap welds
b)Ultrasonic seam welding using the roller as the sonotrode

9. Important parameters of the
US welding process
• The vibrational frequency, ranging between 10kHz and
150 kHz.
• The vibrational amplitude of the welding tip. This quantity
ranges roughly between 0.5 and 30 μm.
• The duration of the welding operation, the welding time,
ranges from 10 ms up to several seconds.
• The clamping pressure in the weld area. This pressure
equals approximately 0.1 to 0.3 times the Vickers
hardness of the material to be welded.

10. Special characteristics of
ultrasonic metal welding
• Metals with widely different melting points
can be welded (e.g. Al to Cu).
• Thin foils or wires can be welded to much
thicker parts.
• Temperature in the weild area is below the
melting point of the welded material
• No fluxes or protective gas are needed.

11. Disadvantages
• Restricted to join thin materials
• Competitively not economical
• Materials being welded may tend to weld
to the tip and anvil
• Welding thermoplastic elastomers is
problematic
• Product is exposed to vibrations during
welding

12. Application
• In microelectronics, wires and ribbons of
Au, Al and Cu with a thickness ranging
from 25 pm to 500 pm are welded
ultrasonically to metallized substrates
• Welding of Al and Cu in various
applications, e.g. electrical leads, closure
welds of tubes and cans, containing
volatile or explosive sub stances.

13. Any Question?

14. Thank you!