ultrasonic welding

this presentation is about ultrasonic welding ,it shows what is ultra sonic welding and how does it work with some applications .
I am a student at port said university ,faculty of engineering ,production and mechanical design department .

1. Ultrasonic welding Made by : Mohamed hamdy mandoh Mohamed nasr aboelhamayel Nader salama ebrahim Presented to: Dr . Hassan abd elhafez

2. 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 APPLICATION

3. 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 .

4. Flow chart of solid state welding

5. MAIN PARTS TRANSDUCER Produces high frequency ultrasonic vibrations. CONVERTOR Converts the electrical signal into a mechanical vibration

6. BOOSTER Modifies the amplitude of vibrations SONOTRODE Applies the mechanical vibrations to the parts to be welded Anvil MAIN PARTS

7. Ultrasonic Welding Mechanism A static clamping force is applied perpendicular to the interface between the work pieces. The contacting sonotrode oscillates on the interface. Combined effect of static and oscillating force produces deformation which promotes welding . Anvil Sonotrode tip Clamping force wedge Transducer Force workpiece 10-75 KHz

8. Principle of Ultrasonic Welding Anvil Mass Sonotrode tip Clamping force wedge Transducer Force Weldment Vibration *In US welding, frictional heat produced by the ultrasonic waves and force is used for joining process. *US waves(15to60 kHz) are transferred to the material under pressure with a sonometer . Welding times are lower than 3 s . * It can proceed with or without the application of external heat.

9. Ultrasonic Welding Power Generation 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, W*s (J) H = Vickers hardness number T = thickness of the sheet Electrical energy Frequency Converter Vibratory transducer

10. 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.

11. 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.

12. Types of US welding Spot Welding Line Welding - Linear Sonotrode Continuous Seam Welding - Roller Sonotrode

13. . Types of Ultrasonic Welding

14. Sonotrode Tip and Anvil Material High Speed Tool Steels used to weld Soft Materials Aluminum Copper Iron Low Carbon Steel Hardenable Nickel-Base Alloys used to weld Hard, High Strength Metals and Alloys

15. Advantages of Ultrasonic Welding 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

16. Limitations of Ultrasonic Welding 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

17. Applications of Ultrasonic Welding 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

18. Applications Manufacturing of toys Joining of electrical and electronic components Welding aluminium wire and sheet Mobiles, sports shoes , laminations, cars……. Packing , medical industries, computers. 6/8/2014 SUBHASIS.....MIT BBSR 21

19. Thank you