ultrasonic-welding-828-SNggldd.pptx

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This document summarizes a seminar presentation on ultrasonic metal welding. It describes how ultrasonic welding works by applying high frequency vibrations and pressure to join metals without melting. The vibrations generate a smaller grain size in the metal, increasing its strength. Frequencies between 20-60 kHz are used to create strong, rigid joints between combinations of metals like aluminum and steel. Prior research studies discussed examine using nonlinear dynamics to model friction forces during welding and how ultrasonic treatment after thermal welding reduces stresses and improves joint strength. The objectives of ultrasonic metal welding are to increase strength, reliability and reduce residual stresses and deformations compared to conventional welding.

Business

UNDER ADMINISTRATIVE SUPPORT
PIMPRI CHINCHWAD EDUCATION TRUST (PCET)
NMVPM
NUTAN MAHARASHTRA INSTT. OF ENGG. & TECH.
MECHANICAL ENGINEERING DEPARTMENT
A.Y 2018-19
A
Seminar Presentation
on
“ULTRASONIC METAL WELDING”
Presented By-
SAGAR M. SALUNKE (TEMB141)
Guide By-
Prof. KALYANI KATOLE

Abstract:
• The ultrasonic effect upon the molten metal generates a
smaller grain size, giving the metal more strength.
• Ultrasonic welding combines pressure and high frequency
vibration motions to form a solid state bond.
• The range ultrasonic frequency used in this welding is from
20kHz to 60kHz. This cool, strong weld capable of joining
such combination as aluminium to steel, aluminium to
tungsten, aluminium to molybdenum and nickel to brass.
• Ultrasonic welding has also made it possible to join metals
with vastly different melting temperatures, making strong
rigid joints. Thus many applications previously considered
unweldable can now revaluated

Introduction:
 In 1938, Lludwig Bergman and some colleagues
were experimenting with ultrasonic waves and
their effects on metal.
 He found that many metals could be combined by
using ultrasonic welding that could not be joined
by any other method.
 It was also found that any metal could be
strengthened by subjecting the metal in its molten
state to ultrasonic vibrations

Literature Survey:
 Research Papers Reffered:
1.Nonlinear Dynamic Analysis of Ultrasonic Metal
Welding Using a Harmonic Balance Method(2018)
2. Technology of thermal welding with ultrasonic weld
joint treatment (2017)
3.Ultrasonic welding of Bimetals (2016)

1.Nonlinear Dynamic Analysis of Ultrasonic Metal
Welding Using a Harmonic Balance Method(2018)
 Ultrasonic welding is a widely used industrial technique
whereby high-frequency ultrasonic vibrations are locally
applied to two or more workpieces being held together
under pressure to create first heat and ultimately a solid-
state weld. In the welding process, stick, slip and
separation occur at the interfaces between adjacent
workpieces.
 Remark:In this study, a new methodology is proposed to
predict the friction forces by introducing a nonlinear
contact model and simulate the coupled thermal-
mechanical interaction. Mixed programming of MATLAB
and ANYSYS is developed with a harmonic balance method

 2. Technology of thermal welding with ultrasonic weld joint
treatment (2017)
The paper describes an innovative technology of thermal
welding with ultrasonic weld joint treatment as applied to
aluminum sliding formworks used in NPP construction.
Ultrasonic treatment in the process of welding greatly
increases the strength of formwork weld joints by reducing
their residual stresses, grain size and degassing.
Remark:
The paper presents the results of theoretical and
experimental studies of ultrasonic effects on the welded
joints and heat-affected zone.

 3.Ultrasonic welding of Bimetals (2016)
 The recent drive towards light weight construction in the
aerospace and automotive industries has increased
treamendously.
 Remark:
 Suitable joining methods are necessary in order to reliably
join materials like aluminium, copper etc.
 i.e.ultrasonic welding of bimetals.

Objectives:
 Increasing the strength, reliability and durability of welded
structures is an important problem in welding engineering.
A significant influence is exerted by residual stresses.
Uneven heating of the product during welding causes its
uneven temperature deformation. The product material
solidity prevents the free temperature deformation of its
individual parts, resulting in the formation of stresses and
plastic deformation of some parts of the joint metal during
welding, and after cooling, welding stresses and
deformations remain in the product
 So, Ultrasonic metal welding plays important role.

This document summarizes a research paper that investigated the effect of heat input on the tensile strength of butt weld joints using MIG welding. The researchers found that increasing heat input affected the microstructure of the base metal and heat affected zone. Tensile strength decreased with higher heat input. Microhardness was observed to increase in the weld pool but decrease in the heat affected zone with greater heat input. Optical microscopy showed smaller dendrite sizes and spacing at low heat input compared to larger dendrites and spacing at high heat input. The extent of grain coarsening in the heat affected zone also increased with higher heat input. In conclusion, welding heat input significantly influences the properties of welded joints.

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