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2-2 Ultrasonic Welding
2-2 Ultrasonic Welding
Ultrasonic Welding
Learning Activities
Lesson Objectives 1. View Slides;
When you finish this lesson you will 2. Read Notes,
understand: 3. Listen to lecture
• Ultrasonic Welding Definition, 4. Do on-line
Characteristics, Process & Applications workbook
• Ultrasonic Power Generation
• Interfacial Interactions & Dissimilar
Metals Welding
S o lid
S ta te C h e m ic a l
W e ld in g
F r ic tio n
U lt r o s o n ic
M e c h a n ic a l P re s s u re
W e ld
Definition of Ultrasonic Welding
A solid state welding process in which
coalescence is produced at the faying
surfaces by the application of high
frequency vibratory energy while the
work pieces are held together under
moderately low static pressure.
Ultrasonic Welding
Process
Clamping
force
Process Mass
• Components of
Sonotrode
ultrasonic welding tip
– Transducer Anvil
– Sonotrode Force
– Anvil
Ultrasonic Welding Mechanism
Clamping
force
• A static clamping force is applied Mass
perpendicular to the interface
between the work pieces.
• The contacting sonotrode oscillates wedge Transducer
• Spot Welding
• Ring Welding
• Line Welding - Linear Sonotrode
• Continuous Seam Welding - Roller Sonotrode
• Microminiature Welding
Typical 1500 ultrasonic
spot-type welding machine
Courtesy AWS handbook
AWS Welding Handbook
100 W
Lateral Drive
Ultrasonic
Welder
• Ultrasonic power
• Clamping force
• Welding time
• Frequency
• Linear Vibration Amplitude
Power Generation
Ultrasonic Welding Power
Generation
• Electrical power of 60
Hz is supplied to the
frequency converter. Electrical
energy
Frequency
converter
• The frequency
Transducer
converter converts the
required 60 Hz signal
Vibratory
to the welding transducer
frequency (from 10 to
75 kHz).
AWS Welding Handbook
Power Generation
Ultrasonic Welding Power
Generation
• Frequency is transformed to
vibration energy through the
transducer.
Frequency
• Energy requirement established Electrical
Converter
energy
through the following empirical
relationship.
– E = K (HT)3/2
– E = electrical energy
– H = Vickers hardness number Vibratory
transducer
– T = thickness of the sheet
Power Requirements
3/2
E = K(HT )
Where:
E = electrical energy, W*s (J)
k = a constant for a given welding system
H = Vickers hardness number of the sheet
T = thickness of the sheet in contact with the sonotrode
tip, in. (mm)
The constant “K” is a complex function that appears to involve primarily
the electromechanical conversion efficiency of the transducer, the
impedance match into the weld, and other characteristics of the welding
system. Different types of transducer systems have substantially different
K values.
Source AWS handbook
AWS Welding Handbook
AWS Welding Handbook
Sonotrode Tip and Anvil Material
High Speed Tool Steels Used to Weld
• Soft Materials
• Aluminum
• Copper
• Iron
• Low Carbon Steel
Material Welded
Metal Film
Non-Metallic
AWS Welding Handbook
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
Applications of Ultrasonic
Welding
• 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
AWS Welding Handbook
Note weld progression (no weld in center) AWS Welding Handbook
Starter motor armature with wires
joined in commutator slots by
ultrasonic welding
Ultrasonically welded Helicopter
access door.
Courtesy AWS handbook
Field coil assembled by ultrasonic welding
Courtesy AWS handbook
AWS Welding Handbook
Wire Bundle Placed in Jaws
Ultrasonic
Tying Tool
Bundled Wires
Welds
Sonatrode
Anvil
Gas Generating
Explosive Powder
Plastic Cap
Primer
Welded to
Plastic Base
Ultrasonic Weld