ulttrasonic metal welding

ULTRASONIC METAL WELDING

APRESENTATION

ON

SUBMITTED TODept. Of Mechanical Engg.Govt. Engg. College, Ajmer

SUBMITTED BYDeepak Kumar Solanki10ME20

GUIDED BYRespectedBD Gidwani Sir &VK Verma Sir

Ultrasonic Welding

Lesson ObjectivesWhen you finish this lesson you will understand:• Ultrasonic Welding Definition, Characteristics, Process & Applications• Ultrasonic Power Generation• Interfacial Interactions & Dissimilar Metals Welding

Learning Activities1. View Slides; 2. Read Notes, 3. Listen to lecture4. Do on-line

workbook

Keywords: Ultrasonic Welding, Transducer, Sonotrode, Anvil

Ultrasonic Welding Process

• Components of ultrasonic welding system include:– Transducer– Sonotrode– Anvil Anvil

Mass

Sonotrode tip

Clampingforce

wedge Transducer

Force

WeldmentVibration

• Clamping force• Welding time • Trigger Point• Frequency • Linear Vibration Amplitude• Welding Tools• Ultrasonic Power

Ultrasonic Welding Variables

Ultrasonic Welding 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

AWS Welding Handbook

• 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, W*s (J)

– H = Vickers hardness number

– T = thickness of the sheet

Electrical energy

Frequency Converter

Vibratory transducer

Ultrasonic Welding Power Generation

Source AWS handbook

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

• Localized temperature rises resulting from interfacial slip and plastic deformation.

• Temperature is also influenced by power, clamping force, and thermal properties of the material.

• Localized Plastic Deformation• Metallurgical phenomena such as

recrystallizing, phase transformation, etc. can occur.

Ultrasonic Welding Interfacial Interaction

Source AWS handbook

Ultrasonic Welding Materials Combinations

Extreme InterpenetrationNickel Foil (top) to Gold-Plated Kovar Foil

Local Plastic FlowDark Regions are Trapped OxideNickel Foil (top) to Molybdenum Sheet

Very Little Penetration, Thin Bond Line, Fiber FlowMolybdenum Sheet to Itself


AWS Welding HandbookComparison With Resistance Spot Weld

• No heat is applied and no melting occurs• Permits welding of thin to thick sections• Welding can be made through some surface

coatings• Dissimilar metals having vastly different

melting points can be joined• Pressures used are lower, welding times are

shorter, and the thickness of deformed regions are thinner than for cold welding

Advantages of Ultrasonic Welding

• The thickness of the component adjacent to the sonotrode tip is restricted 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 work pieces and applying clamping force.

• Due to fatigue loading the life of equipment is short.

Limitations of Ultrasonic Welding

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

0.1.1.2.5.T25.95.12

• Assembling of electronic components such as diodes and semiconductors with substrates

• Electrical connections to current carrying devices including motors, field coils, and capacitors

• Encapsulation and packaging• Plastic parts• Fabricating nuclear fuel elements• In aircraft structural applications.

Applications of Ultrasonic Welding