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ULTRASONIC WELDING PROCESS
- 3. A solid state welding process in which coalescence is produced at the faying surfaces by the application of high frequency vibratory energy while the work pieces are held together under moderately low static pressure. Definition of Ultrasonic Welding
- 4. Ultrasonic Welding Process Process Description: • Components of ultrasonic welding system include: – Transducer – Sonotrode – Anvil Anvil Mass Sonotrode tip Clamping force wedge Transducer Force Weldment Vibration
- 5. • A static clamping force is applied perpendicular to the interface between the work pieces. • The contacting sonotrode oscillates parallel to the interface. • Combined effect of static and oscillating force produces deformation which promotes welding. Anvil Mass Sonotrode tip Clamping force wedge Transducer Force workpiece Ultrasonic Welding Mechanism 10-75 KHz
- 6. Process Variations • Spot Welding • Ring Welding • Line Welding - Linear Sonotrode • Continuous Seam Welding - Roller Sonotrode • Microminiature Welding
- 7. Typical 1500 ultrasonic spot-type welding machine Courtesy AWS handbook
- 9. AWS Welding Handbook 100 W Lateral Drive Ultrasonic Welder
- 10. AWS Welding Handbook Typical Ring Welding Applications Tip in Shape of Weld
- 11. AWS Welding Handbook Attachment for Continuous Ring Welding
- 12. AWS Welding Handbook Traversing Head for Continuous Seam Welding Tip
- 13. • Ultrasonic power • Clamping force • Welding time • Frequency • Linear Vibration Amplitude Welding Variables Ultrasonic Welding Variables
- 14. 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 Power Generation
- 16. • 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 – H = Vickers hardness number – T = thickness of the sheet Electrical energy Frequency Converter Vibratory transducer Power Generation Ultrasonic Welding Power Generation
- 17. 2 / 3 ) HT ( K E Where: E = electrical energy, W*s (J) k = a constant for a given welding system H = Vickers hardness number of the sheet T = thickness of the sheet in contact with the sonotrode tip, in. (mm) Power Requirements The constant “K” is a complex function that appears to involve primarily the electromechanical conversion efficiency of the transducer, the impedance match into the weld, and other characteristics of the welding system. Different types of transducer systems have substantially different K values.
- 21. 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
- 22. • 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
- 23. Source AWS handbook Ultrasonic Welding Materials Combinations
- 24. 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
- 25. AWS Welding Handbook Comparison With Resistance Spot Weld
- 26. • No heat is applied and no melting occurs. • Permits welding of thin to thick sections. • Welding can be made through some surface coatings. • Pressures used are lower, welding times are shorter, and the thickness of deformed regions are thinner than for cold welding. Advantages of Ultrasonic Welding
- 27. • The thickness of the component adjacent to the sonotrode tip must not exceed relatively thin gages 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 workpieces and applying clamping force. Limitations of Ultrasonic Welding
- 28. Other Process Variations • Ultrasonic Welding of Non-metallic • Ultrasonic Plastic Welding
- 29. Welds Can Be Made to Non-Metallic Substrate Materials Coated with Thin Layers of Metal Films Non-Metallic Metal Film Material Welded
- 31. 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
- 33. • 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 Applications of Ultrasonic Welding
- 35. AWS Welding Handbook Note weld progression (no weld in center)
- 36. Starter motor armature with wires joined in commutator slots by ultrasonic welding Ultrasonically welded Helicopter access door. Courtesy AWS handbook
- 37. Field coil assembled by ultrasonic welding Courtesy AWS handbook
- 39. Ultrasonic Horn First Weld Made Cut and Second Weld Made Bundled Wires Welds Ultrasonic Tying Tool Metal Tape Fed Around bundle of Wires and welded once, then cut and welded again. Wire Bundle Placed in Jaws
- 40. Ultrasonic Stitch (Clad) Welding Anvil Sonatrode Louks, et al “Ultrasonic Bonding Method” US Patenet 6,099,670 Aug. 8, 2000
- 41. Ultrasonic Welding of Eraser Holder on Plastic Pencil Coinon, A, Trajber, Z, “Pencil Having and Eraser-Holding Ferrule Secured by Ultrasonic Welding” US Patent 5,774,931 July 7, 1998
- 42. Explosive Gas Generator For Auto Air Bag (Plastic Ultrasonic Weld) Plastic Cap Welded to Plastic Base Gas Generating Explosive Powder Primer Ultrasonic Weld Avory, et al “Electrical Initiator” US Patent 5,763,814 June 9, 1998.