ultrasonic metal welding

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3/5/12

Ultrasonic Metal Welding

By Mohd Sharieff.08081A0337.


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INTRODUCTION.

• Ultrasonic welding combinespressure and high frequencyvibration motions to form a solid

state bond between two metals.

•

Possible to join metals with differentmelting temperatures, making strongrigid joints.

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Equipment

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• ULTRA SONIC GENERATOR: The

ultra sonic generator operates withac line voltage (220/110 V). Itgenerates a sinusoidal wave of 20

kHz from the supplied power.

IMPORTANT FEATURE:

• The automatic tuning adjustmentcompensates for changes andensures optimal efficiency. This is

extremely important for ultra sonic44



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ULTRASONIC TRANSDUCER

SYSTEM• The ultrasonic transducer system

consists of three parts;

• Converter.

• Booster.

•

Sonotrode. 55



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• THE CONVERTER:

Transforms thehigh frequency electric energy

produced by the generator intomechanical energy.

• THE BOOSTER: Serves as an

amplitude transformer for therequired amplitude range as well as ageneral stabilizer for the oscillationsof the transducer system.

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THE ANVIL AND FIXTURES: Theparts to be welded are insertedbetween anvil and sonotrode and

overlap each other.

• Keeps the work piece in position

• Secures it against any incontrollablemovement.

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WORKING.

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The Parameters:

• Clamping Pressure

•

Welding Time

• Amplitude

• Ultrasonic Frequency

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The Pros

• Surface preparation not critical

• No Defects

•

No fumes or odours• No filler metal

• Very thin metals can be welded too.

• Minimum Surface Deformation

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The Cons

• Materials tend to weld to the tip of

the anvil.

• Ductile metals yield to the pressure

• Short life span of equipment

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Applications

• Joining of electrical and electroniccomponents.

• Welding aluminum wire and sheets.

• Fabricating nuclear fuel elements.

•

In aircraft structural applications.1313



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Conclusion• In conclusion ultrasonic welding has

many advantages over other weldingtechniques for many type e of

connections. These include speed,cost, reliability and many others.However, it should also be made

clear that it is only ideal for arelatively small proportion of all of the possible joints. Ultrasonicwelding should not be seen as areplacement for other techniques,1414

ultrasonic metal welding

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