ULTRASONIC WELDING

SUBMITTED TO- SUBMITTED BY :

DR. A.K SHARMA 13001004007
DR. RAJKUMAR BHANU PARTAP
MECH(4th YEAR)
 CONTENTS
• INTRODUCTION
• WHY TO USE US WELDING
• ULTRASONIC WELDING PROCESS
• ULTRASONIC WELDING MECHANISM
• PRINCIPLE OF ULTRASONIC MACHINING
• JOINT FORMS WITH ULTRASONIC MACHINING
• SPOT WELDING IN AIRCRAFT WINGS
• ADVANTAGES
• DIS ADVANTAGES
 INTRODUCTION

• Ultrasonic welding is an industrial technique whereby

high-frequency ultrasonic acoustic vibrations are
locally applied to work pieces being held together
under pressure to create a solid-state weld.
FLOW CHART OF SOLID STATE WELDING

Electrical

Solid
State Chemical
Welding
Friction

Ultrosonic
Mechanical Pressure
Weld
 MAIN PARTS
TRANSDUCER
Produces high frequency
ultrasonic vibrations.

CONVERTOR
Converts the electrical signal
into a mechanical vibration
 MAIN PARTS
• BOOSTER
• Modifies the amplitude
of vibrations

• SONOTRODE
• Applies the mechanical
vibrations to the parts
to be welded
 ULTRASONIC WELDING MECHANISM
 A static clamping Clamping force
force is applied
perpendicular to the
interface between Mass
the work pieces.
 The contacting wedge Transducer
sonotrode oscillates
on the interface.
Sonotrode
 Combined effect of tip
static and oscillating
force produces Vibration workpiece
deformation which
promotes welding. Anvil
Force
10-75 KHz
 Clamping
force

Mass
*In US welding, frictional heat
produced by the ultrasonic waves
and force is used for joining wedge Transducer
process.
*US waves(15to60 kHz) are Sonotrode
transferred to the material under tip

pressure with a sonometer.

Vibration Weldment
Welding times are lower than 3 s.
*It can proceed with or without Anvil
the application of external heat. Force
US WELDING POWER GENERATION
• Frequency is transformed to
vibration energy through
the transducer.
Frequency
• Energy requirement Electrical
energy Converter
established through the
following empirical
relationship.
– E = K (HT)3/2
– E = electrical energy, W*s (J) Vibratory
transducer
– H = Vickers hardness
number
– T = thickness of the sheet
 INTERFACIAL INTERACTION
 Localized Plastic
Deformation
 Localized temperature rises
resulting from interfacial slip
and plastic deformation.
 Temperature is also
influenced by power,
clamping force, and thermal
properties of the material.
 Metallurgical phenomena
such as recrystallizing, phase
transformation, etc..... can
occur.
 WHY TO USE US WELDING?
• First - Ultrasonic assembly uses ultrasonic vibratory
energy which is transmitted through the parts to melt
and bond thermoplastic materials And joining thin sheet
gauge metals and other lightweight materials
• Second - This technique is fast, efficient, non-
contaminating .
• Third - In ultrasonic welding, there are no connective
bolts, nails, soldering materials, or adhesives necessary
to bind the materials together.
 TYPES OF US WELDING
• Spot Welding

• Line Welding
• - Linear Sonotrode

• Continuous Seam
Welding
• - Roller Sonotrode
• .
 ADVANTAGES

• 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
 LIMITATIONS

• Competitively not economical

• 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.
• This process is limited to small welds of thin, malleable
metals Eg: Aluminium, Copper, Nickel
 APPLICATIONS

 Computer and electrical industries delicate

circuits, Junctions of wire harnesses , flash drives and
computer disks, Semiconductor devices

• Aerospace and automotive industries instrument
panels, door panels, lamps, air ducts, steering wheels,
and engine components

• Medical industry
 APPLICATIONS
• Manufacturing of toys
• Joining of electrical and electronic components
• Welding aluminium wire and sheet
• Mobiles, sports shoes , laminations, cars…….
• Packing , medical industries, computers.