Techniques for ultrasonic welding of metals.

1. Copper Tube Sealer
Ultrasonic Welding
Machine
By
Schunk Sonosystem GmbH
Siam Create Enterprises Co.,ltd.
3/24/2023 1
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

2. Basic of Ultrasonic Concept
• Solid State Welding Electrical
Chemical
Mechanical Friction Pressure
Ultrasonic
Weld
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.
3/24/2023 2
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

3. Process Description:
Components of ultrasonic welding system include:
• Transducer
• Sonotrode
• Anvil
3/24/2023 3
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

4. Ultrasonic Welding Mechanism
• 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.
3/24/2023 4
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

5. Ultrasonic Welding Mechanism
Anvil
Mass
Sonotrode
tip
Clamping
force
wedge Transducer
Force
workpiece
10-75 KHz
3/24/2023 5
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

6. Ultrasonic Welding Variables
• Ultrasonic power ( Energy, Ws.)
• Clamping force (Pressure ,Bar)
• Welding time ( Time ,Sec.)
• Frequency (Vibration ,Hz.)
• Linear Vibration Amplitude (Thickness ,mm.)
3/24/2023 6
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

7. Ultrasonic 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
3/24/2023 7
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

8. Ultrasonic Power Generation
• 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 wall
Electrical
energy
Frequency
Converter
Vibratory
transducer
3/24/2023 8
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

9. 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
3/24/2023 9
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

10. Ultrasonic Welding Interfacial
Interaction
• Localized temperature rises resulting from
interfacial slip and Copper deformation.
• Temperature is also influenced by power,
clamping force, and thermal properties of the
material.
• Localized Copper Deformation
• Metallurgical phenomena such as recrystallizing,
phase transformation, etc..... can occur.
3/24/2023 10
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

11. Ultrasonic Welding Materials
Combinations
Source AWS handbook
3/24/2023 11
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

12. Advantages of Ultrasonic
Welding
• 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
3/24/2023 12
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

13. Limitations of Ultrasonic Welding
• 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.
3/24/2023 13
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

14. Other Process Variations
• Ultrasonic Welding of Non-metallic
• Ultrasonic Plastic Welding
Welds Can Be Made to Non-Metallic
Substrate Materials Coated with Thin
Layers of Metal Films
Non-Metallic
Metal Film
Material Welded
3/24/2023 14
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

15. 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
3/24/2023 15
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

16. Basic Elements of Kobra EX/EL
Sonotrode Booster Converter
Welding Part
Anvil
Ultrasonic Contrller
Power Supply
3/24/2023 16
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

17. Description of Machine
Safety Fuse
A) 2 Amp. B) 12.5 Amp.
Tools
A) Sonotrode
B) Anvil
Main Supply : 230+/- 15% VAC
50/60 Hz. Single Phase / Grounded
Power Consumpation : Max. 3,000 Watt.
Fuse Operation : 16 Amp.
Compressed Air Supply in front of the maintenance unit
: 6.5 – 10 Bar / Dry & Oil Free
Main Air Consumption : approx. 75 L/min. at 6 Bar
3/24/2023 17
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

18. The Welding tools Adaptation
Right-hand cut tools Left-hand cut tools
3/24/2023 18
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

19. Important Tools
Right Left Double No Left Cut
Round
Right Cut
Round
Special applications
A
B
3/24/2023 19
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

20. Welding head & Fork
A: Fork
3/24/2023 20
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

21. Corrected Insertion of Tube
3/24/2023 21
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

22. Table of Parameter (Standard
Values for Left/Right Cut)
3/24/2023 22
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

23. Initial Operation
3/24/2023 23
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

24. Initial Operation
Right /Left Cut No Cut Double Cut
3/24/2023 24
Presented by Mr.Patpitchayut Surote Siam
Create Enterprises Co.,Ltd.

25. Left & Right Cut Tooling
- Loosen 2 Set screws on both side
- Adjust the gap btw Sonotrode and Anvil by a
filler guage 0.40 mm. in lateral direction.
- Tighten set screws on both side and
perform calibration
3/24/2023 25
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

26. Left & Right Cut Tooling
For a wall thickness 0f the tube of
0.75 mm. use filer gauge  0.65 mm.
Final height amounts to  0.95 – 1.05 mm. (i.e.~ 1.00 mm.)
For a wall thickness 0f the tube of
1.00 mm. use filer gauge  0.90 mm.
Final height amounts to  1.20 – 1.30 mm. (i.e. > 1.20 mm.)
3/24/2023 26
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

27. Height Sensor Calibration
After the exchange of the tooling or the height sensor, a calibration 0f the
Absolute height measuring system will be necessary.
Activation of calibration will have to used Feeler Gauge of 1 mm.
After press button with clamping to feeler gauge 1 mm. and second time
For calibration of 2 mm. feeler gauage.
3/24/2023 27
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.

28. Test Parameter
Table of wall Thickness / Thickness of the feeler gauge
Feeler Gauge Copper Tube
Thickness Thickness
0.55 0.45
0.75 0.65
1.00 0.75
3/24/2023 28
Presented by Mr.Patpitchayut Surote
Siam Create Enterprises Co.,Ltd.