Ultrasonic Welding
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Here I have explained theoretical view of ultrasonic welding and its applications in real world. In addition to that, advantages and disadvantages of this process also discussed.
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Ultrasonic Welding
- 1. ULTRASONIC WELDING KARUNATHILAKA R M B D M KARUNARATHNE D G N D KARUNATHILAKA P R H
- 2. WE ARE GOING TO DISCUSS ABOUT, • What is ultrasonic welding • Ultrasonic welding process • Applications of ultrasonic welding • Advantages and limitations of ultrasonic welding
- 3. Solid state welding Chemical Electrical Mechanical Friction Pressure Deformation Pressure Ultrasonic welding Pressure Deformation
- 4. WHAT IS ULTRA SONIC WELDING? • High-frequency ultrasonic acoustic vibrations are used. • Holds both surfaces that needed to be welded under pressure during the process. • Finally creates a solid-state weld.
- 5. ULTRA SONIC WELDING PROCESS • Both surfaces are kept together. • One of the materials usually has a spiked energy director which contacts the second plastic part. • The ultrasonic energy melts the point contact between the parts, creating a joint.
- 6. ULTRA SONIC WELDING PROCESS… • The oscillating is given by transducer to the sonotrode. • 15kHz - 70 kHz vibration range for thermoplastics. • In thermoplastics weld occur by reaching local melting of the plastic due to absorption of vibrational energy along the joint to be welded.
- 7. ULTRA SONIC WELDING PROCESS… • In metals, welding occurs due to high-pressure dispersion of surface oxides and local motion of the materials. • Although there is heating, it is not enough to melt the base materials.
- 8. TYPES OF ULTRA SONIC WELDING • Spot welding.
- 9. TYPES OF ULTRA SONIC WELDING • Line welding.
- 10. TYPES OF ULTRA SONIC WELDING • Continuous Seam welding.
- 11. TYPES OF ULTRA SONIC WELDING • Ring welding.
- 13. APPLICATIONS OF ULTRA SONIC WELDING. • Automobiles • Assemble large plastic and electrical components - instrument panels, door panels, lamps, air ducts, steering wheels, upholstery and engine components. • Diesel injector. • Universal joint yoke. • Gear hub.
- 14. APPLICATIONS OF ULTRA SONIC WELDING. • Medical sector • Types of filters, IV catheters, dialysis tubes, pipettes, cardiometry reservoirs, face masks • Items like hospital gowns, sterile garments, masks, transdermal patches and textiles for clean rooms can be sealed and sewn.
- 15. APPLICATIONS OF ULTRA SONIC WELDING. • Packaging industry • explosives, fireworks. These items require hermetic sealing, can’t expose to high temperatures. • butane lighter. • Food packaging • Milk and juice containers • Paper parts to be sealed are coated with plastic, generally polypropylene or polyethylene
- 16. APPLICATIONS OF ULTRA SONIC WELDING. • Aerospace/Marine industry. • Wire terminations and splicing in electrical and electronics industry. • Twist drills • Drill pipes • Spindles • Tapers
- 17. ADVANTAGES OF ULTRASONIC WELDING • No need of external heat generation. • Dissimilar materials can be jointed. • Heat affected zone is minimum. • Surface deformation is less and no waste material is generated. • Very thin materials can be welded and weld is localized. • No defects due to gases , arc and filter metal. • Welding time is minimum. (Lower than 3s)
- 18. 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. • Comparatively expensive. • The weld can not withstand higher stresses. • Only thin and soft metals can be welded.