JAIPUR ENGINEERING COLLEGE

Production Engineering

SEMINAR
ON
ULTRASONIC WELDING
SUBMITTED BY – MANISH KUMAR

ROLL NO- 19EJEPE603

SUBMITTED TO – Mrs. PINKI MAURYA (HOD)
 Content
1.Introduction of Welding
2. Classification of welding
3. Ultrasonic welding
4. Why we use ultrasonic welding?
5. Principle of US welding
6. Components of US welding
7. Joints forms with US welding
8. Advantages of US welding
9. Disadvantages of US welding
10. Application
11. Safety & Precautions
Conclusion

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 INTRODUCTION OF WELDING

“Welding is a fabrication process whereby two or more parts are fused together by
means of heat, pressure or both forming a join as the parts cool. Welding is usually
used on metals and thermoplastics but can also be used on wood. The
completed welded joint may be referred to as a weldment.”

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 Classification of welding

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 Ultrasonic welding
Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic
vibrations are locally applied to work piece being held together under pressure to
create a solid-state weld. It is commonly used for plastics and metals, and especially
for joining dissimilar materials.

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 Why we use US welding?
1. Ultrasonic assembly uses ultrasonic vibratory energy
which is transmitted through the parts to melt & bond
thermoplastic materials & joining thin sheet gauge metals
& other lightweight materials.
2. This technique is faster, efficient, non-contaminating &
requires no consumables.
3. In ultrasonic welding, there are no connective bolts, nails,
soldering materials, or adhesives necessary to bind the
materials together.

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 Principle of US welding
In US welding, frictional heat produced by the ultrasonic
waves & force is used for joining process. Ultrasonic
waves(15 to60kHz) are transferred to the material under
pressure with a sonometer. Welding times are lower than 3
sec. The welding can proceed with or without the application
of external heat.

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 Components of US welding
• All ultrasonic welding systems are composed of the same basic elements:
• A press, usually with a pneumatic or electric drive, to assemble two parts
under pressure
• A nest or anvil or fixture where the parts are placed and allowing the high
frequency vibration to be directed to the interfaces
• An ultrasonic stack composed of a converter or piezoelectric transducer an
optional booster and a sonotrode (US: Horn). All three elements of the
stack are specifically tuned to resonate at the same exact ultrasonic
frequency (Typically 15, 20, 30, 35 or 40 kHz)
– Converter: Converts the electrical signal into a mechanical vibration using piezo
electric effect.
– Booster: Modifies the amplitude of the vibration mechanically. It is also used in
standard systems to clamp the stack in the press.
– Horn or sonotrode: Takes the shape of the part, also modifies the amplitude
mechanically and Applies the mechanical vibration to the parts to be welded.
• An electronic ultrasonic generator (US: Power supply) delivering a high
power electric signal with frequency matching the resonance frequency of
the stack.
• A controller controlling the movement of the press and the delivery of the
ultrasonic energy.

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Components of US welding:

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 Joints forms with US welding

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 Advantages

1. No need of external heat generation.

2. Dissimilar materials can be weld.
3. Heat affected zone is minimum.
4. Surface deformation is less & no waste material is generated.
5. Very thin materials can be welded & weld is localized.
6. No defects due to gases are & filter metal.
7. Welding time is minimum.

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 Disadvantages

1. The thickness of the component adjacent to the sonotrode tip

must not exceed relatively thin gages because of power
limitations of the equipment.
2. Comparatively expensive.
3. The weld can not withstand higher stresses.
4. Only thin and soft metals can be welded.

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 Applications

1. Manufacturing of toys.
2. Joining of electrical & electronics components.
3. Welding aluminium wire & sheet.
4. Mobiles, sports shoes, laminations etc.
5. Packing, medical industries & computers.

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 Safety & precautions

1. Ultrasonic welding machines require routine maintenance and

inspection.
2. Panel doors, housing covers and protective guards may need to
be removed for maintenance This should be done when the
power to the equipment is off and only by the trained
professional servicing the machine.
3. High vibrations noise can be damped by clamping these large
parts at one or more locations. 

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 CONCLUSION

• In this seminar a complete design of the ultrasonic welding is

given. The total assembly is designed taking in account of
currently available components in the market. The designing
and assembling of very large number of components was a
tremendous task and was completed on time. However
because of some parts couldn’t be purchased the whole
assembly was limited to some basic manufacturing operation.

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 Any
Queries

• ANY QUERY

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