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A SEMINOR ON
ULTRASONIC METAL
WELDING
SUBMITTED BY
B.VENKATA SWAMY
ROLL NO:16ME01038
INTRODUCTION
 Ultrasonic welding is an industrial technique
whereby high-frequency ultrasonic acoustic
vibrations are locally applied to work pieces
being held together under pressure to create
a solid-state weld
Why to use US welding?
 First-Ultrasonic assembly uses ultrasonic vibratory
energy which is transmitted through the parts to melt
and bond thermoplastic materials and joining thin
sheet gauge metals and other lightweight materials .
 Second-This technique is fast, efficient, non
contaminating and requires no consumables.
 Third- In ultrasonic welding, there are no connective
bolts, nails, soldering materials, or adhesives necessary
to bind the materials together.
Principal of Ultrasonic welding
 In ultrasonic welding, frictional heat produced by the
ultrasonic waves and force is used for the joining
process. Ultrasonic waves(15 to 60 kHz) are transferred
to the material under pressure with a sonometer .
Welding times are lower than 3 s .The welding can
proceed with or without the application of external
heat.
Main parts
 Transducers: Produce high frequency ultrasonic
vibrations.
 Convertor: Converts the electrical signal in to a
mechanical vibration.
 Booster: Modifies the amplitude of vibrations.
 Sonotrode: Applies the mechanical vibrations to the
parts to be welded.
Working
 The parts are placed between a fixed shaped
nest(anvil) and a sonotrode (horn) connected to a
transducer, and a 20kHz low – amplitude acoustic
vibration is emitted.
 Common frequencies used in ultrasonic welding of
thermos plastics are 15kHz, 20kHz, 30kHz, 35kHz, 40kHz
and 70kHz.
 The ultrasonic energy melts the point between the
parts creating a joint.
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.
Advantages
 Heat affected zone is minimized
 Very thin materials can be welded
 Surface deformation is minimum
 Welding of glass is also possible
 No defects due to gases, arc and filler metal
 Pressure uses are lower, and welding time are shorter
 Dissimilar materials can be joined
 Welding can be made through some surface coating
Disadvantages
 Restricted to join thin materials
 Competitively not economical
 Materials being welded may tend to the
tip(sonotrode) and anvil
Applications
 Manufacturing of toys
 Joining of electrical and electronic components
 Welding aluminium wire and sheet
 Mobiles, sports shoes, laminations, cars,….....
 Packing, medical industries, computers.
THANK YOU

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Ultrasonic welding

  • 1. A SEMINOR ON ULTRASONIC METAL WELDING SUBMITTED BY B.VENKATA SWAMY ROLL NO:16ME01038
  • 2. INTRODUCTION  Ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld
  • 3. Why to use US welding?  First-Ultrasonic assembly uses ultrasonic vibratory energy which is transmitted through the parts to melt and bond thermoplastic materials and joining thin sheet gauge metals and other lightweight materials .  Second-This technique is fast, efficient, non contaminating and requires no consumables.  Third- In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together.
  • 4. Principal of Ultrasonic welding  In ultrasonic welding, frictional heat produced by the ultrasonic waves and force is used for the joining process. Ultrasonic waves(15 to 60 kHz) are transferred to the material under pressure with a sonometer . Welding times are lower than 3 s .The welding can proceed with or without the application of external heat.
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  • 8. Main parts  Transducers: Produce high frequency ultrasonic vibrations.  Convertor: Converts the electrical signal in to a mechanical vibration.  Booster: Modifies the amplitude of vibrations.  Sonotrode: Applies the mechanical vibrations to the parts to be welded.
  • 9. Working  The parts are placed between a fixed shaped nest(anvil) and a sonotrode (horn) connected to a transducer, and a 20kHz low – amplitude acoustic vibration is emitted.  Common frequencies used in ultrasonic welding of thermos plastics are 15kHz, 20kHz, 30kHz, 35kHz, 40kHz and 70kHz.  The ultrasonic energy melts the point between the parts creating a joint.
  • 10. 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.
  • 11. Advantages  Heat affected zone is minimized  Very thin materials can be welded  Surface deformation is minimum  Welding of glass is also possible  No defects due to gases, arc and filler metal  Pressure uses are lower, and welding time are shorter  Dissimilar materials can be joined  Welding can be made through some surface coating
  • 12. Disadvantages  Restricted to join thin materials  Competitively not economical  Materials being welded may tend to the tip(sonotrode) and anvil
  • 13. Applications  Manufacturing of toys  Joining of electrical and electronic components  Welding aluminium wire and sheet  Mobiles, sports shoes, laminations, cars,….....  Packing, medical industries, computers.
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