Ultrasonic Welding
Lesson Objectives When you finish this lesson you will understand: Ultrasonic Welding Definition, Characteristics, Process & Applications Ultrasonic Power Generation Interfacial Interactions & Dissimilar Metals Welding Learning Activities 1. View Slides; 2. Read Notes, 3. Listen to lecture 4. Do on-line workbook
E le c tr ic a l
S o lid S ta te W e ld in g
C h e m ic a l
F r ic tio n
M e c h a n ic a l
P re s s u re
U lt r o s o n ic W e ld
Process Description: Components of Sonotrode ultrasonic welding tip system include: Vibration
Transducer Sonotrode Anvil
Mass
wedge Transducer
A static clamping force is applied perpendicular to the interface between the work pieces. The contacting sonotrode oscillates parallel to the interface. Combined effect of static and oscillating force produces deformation which promotes 10-75 KHz welding.
Mass
Process Variations
Spot Welding Ring Welding Line Welding - Linear Sonotrode Continuous Seam Welding - Roller Sonotrode Microminiature Welding
Tip
Welding Variables
Power Generation
Frequency converter
Transducer
Vibratory transducer
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 H = Vickers hardness number T = thickness of the sheet
Power Generation
Frequency Converter
Vibratory transducer
Power Requirements
E = K(HT )
3/2
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.
Extreme Interpenetration
Nickel Foil (top) to Gold-Plated Kovar Foil
Welds Can Be Made to Non-Metallic Substrate Materials Coated with Thin Layers of Metal Films
Material Welded Metal Film Non-Metallic
Limitations
Equipment complex, many variables Only use on small parts Cannot weld all plastics
0.1.1.2.5.T25.95.12
Starter motor armature with wires joined in commutator slots by ultrasonic welding Ultrasonically welded Helicopter access door. Courtesy AWS handbook
Welds
Anvil
Coinon, A, Trajber, Z, Pencil Having and Eraser-Holding Ferrule Secured by Ultrasonic Welding US Patent 5,774,931 July 7, 1998