Brief discussion on Ultrasnic welding and friction welding, with basic relations, types, analysis and applications

1. SPECIAL METAL JOINING PROCESSES
ULTRASONIC WELDING AND FRICTION WELDING
Presented by
Magesh K
17ME325
I yr M.Tech. Product Design and Manufacturing
PONDICHERRY ENGINEERING COLLEGE
Subject Handling Staff
Dr.K.Mahadevan
Head of the Dept
Mechanical Engineering

2. WELDING
FUSION
WELDING
SOLID
STATE
WELDING
Examples
SMAW
SAW
EBW
Examples
FRW
USW
EXW

3. SPECIAL METAL JOINING
PROCESS
 Also called MISCELLANEOUS WELDING
PROCESS
 These processes are used for improved weld
quality and human comfort
 Both friction welding and ultrasonic welding
comes under SOLID STATE WELDING
SOLID STATE WELDING -PRINCIPLE
If two clean surfaces are brought into close
contact with each other under sufficient pressure,
they form bonds and produce a joint.

4. PHENOMENA INVLOVED
 Diffusion
Transfer of atoms at the interface
 Pressure
 Relative Interfacial Movements

5. VARIOUS SPECIAL METAL
JOINING PROCESSES
 Ultrasonic welding (USW)
 Friction welding (FRW)
 Explosive Welding (EXW)
 Electron Beam Welding (EBW)
 Diffusion Welding OR Diffusion
Bonding(DFW)
 Laser Beam Welding (LBW)
 Thermit Welding (TW)
 Forge Welding (FOW)
 Induction Welding (IW)

6. ULTRASONIC WELDING
 SOLID STATE WELDING PROCESS
 In USW, the coalescence is produced by
the local application of high frequency
vibratory energy as the work parts are
held together under high pressure

7. Stresses
involved
• Static Normal
Stress
•Tangential
Shear stress
PROCESS

8. KEY POINTS TO BE NOTED
 Electrode is called ‘Sonotrode’
 No fusion or melting
 Temperature at the weld zone = 1/3 to 1/5
of Tm. However, for joining
thermoplastics, relatively lower
temperature is used
 Dissimilar metals can be welded with
USW (Bimetallic strips)

9. ULTRASONIC SEAM WELDING

10. PARAMETERS
PARAMETER OPTIMUM RANGE
Frequency 10-75 kHz
Period of contact at the
interface
less than 1 second
Thickness •0.005 to 1 mm for steel
•Upto 3 mm for Aluminium
•Upto 10 mm for materials
like organic glass, PVC,
Polyethylene, Vinyl
Chloride, Polystyrene
Force • maximum of 3000N

11. BASIC RELATIONS
 E = PxT
E -Energy input
P - Power
T - Time
 P= F x V
F -Force
V - Speed of movement of tool

12. APPLICATIONS
Polymers used in car
components Medical Apllications

13. OTHER APPLICATIONS OF USW
 Air craft construction
 Building of transistors
 Fine wire assemblies
 Bimetal electrical contacts
 Welding of Aluminium foil for packaging
requirements

14. FRICTION WELDING
 Heat required for
welding is generated
through friction
between the faying
surfaces
 It is a Solid state
welding process
 Subjected to axial
force and torque

15. KEY POINTS TO BE NOTED
 Oxides and other contaminants at the
interface are removed by the radially
outward movement of the hot metal at the
interface
 The rotating member must be clamped
securely to the chuck or collect to resist both
torque and axial forces without slipping
 The pressure at the interface and the
resulting friction produce sufficient heat for a
strong joint to form

16. ANALYSIS

17. UPSET LENGTH
The upset length is the distance the two pieces
move inward during welding after their initial
contact

18. FRICTION WELDING
REAL TIME PICTURE

19. SIZE AND SHAPE OF THE WELD
Size depends on
• The amount of heat generated.
• Thermal conductivity of the
materials.
• Mechanical properties of the
materials being joined at elevated
temperatures
Shape depends on
• Rotational speed and Axial pressure
applied
• Generally solid and tubular shafts

20. MODIFICATIONS OF FRW
 Inertia Friction Welding
 Linear Friction Welding ( W/P need not be
circular)
 Friction Stir Welding
Inertia Friction Welding Linear Friction Welding

21. FRICTION STIR WELDING
•In Friction Stir Welding, (developed in 1991), a
third body is rubbed against the two surfaces to be
joined
•In FRSW, electrode is also called as ‘Mechtrode’

22. FRICTION STIR WELDING
REAL TIME PICTURE

23. PROCESS VARIABLES
 Rotational speed
 Forging pressure
 Time for heating
 Time for braking
 Time for forging

24. PARAMETERS AND
MATERIALS USED
PARAMETERS FRW / IFRW LFRW FRSW
Size Steel solid rod –
<100mm
Steel Pipes - <
250mm
Rectangular
sections as large
as 50mm x
20mm
Probe – 5 to 6
mm dia and 5
mm height
W/P – 1 mm to
50 mm
75 mm thick Al
plates
Surface speed of
rotating member /
Frequency
15m/s 25 Hz (amplitude
+ or - 2 mm)
15 m/s
Pressure Applied 100 MPa for 240 mm2
Temperature 230 to 260 ºC

25. BASIC RELATIONS
 Friction force (F) depends on Area of contact (A)
and applied load (L)
F = αA + μL
 If applied pressure is very high, Area is negligible
and can be neglected
F = μL
μ – Coefficient of friction (<0.3)
H = 2PK/nR x102 W/mm2
H – Heat generated W/mm2;
K – constant (mm2/min2)
N – speed (rpm)
R – Work Radius (mm)

26. APPLICATIONS
Gear Lever Piston Rods
Pump Shafts Engine Valves

27. Space Crafts Apple iMAC
Train Bodies Marine Vessels

28. VALVES

29. REFERENCES
 ‘Manufacturing Engineering and
Technology’ by Serope Kalpakjian and
Steven R Schmid
 ‘A Textbook of Production Technology’
by PC Sharma
 Mehmet UZKUT, Bekir Sadik UNLU,
Selim Sarper YILMAZ, Mustafa
AKDAG,’Friction Welding and its
application in today’s world’
 Brazen – Amplitude Reference Guide

30. Online References
 Wikipedia
 Bing images
 http://www.holroyd.com/blog/friction-stir-
welding-applications/
 https://www.quora.com/What-are-the-
practical-applications-for-ultrasonic-welding
 www.yourarticlelibrary.com/welding/friction
-welding-operations/97490
 www.rinco-usa.com
 www.weldguru.com

31. THANK YOU