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    Ultrasonic Welding

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    Shubhangi Ojha
    Ultrasonic welding is a solid state welding process developed in the 1940s where high-frequency ultrasonic vibrations are used to locally weld materials held together under pressure. It can be used to weld both metals and plastics. The ultrasonic vibrations cause coalescence between the materials without melting. It has advantages over other welding techniques like not producing heat, fumes or odors and allowing dissimilar materials to be joined. However, it is limited to lap joints and thin materials due to power limitations. Ultrasonic welding has applications in electronics, appliances, automotive and medical device assembly.

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    Ultrasonic Welding

    Uploaded by

    Shubhangi Ojha
    559 views25 pages
    Ultrasonic welding is a solid state welding process developed in the 1940s where high-frequency ultrasonic vibrations are used to locally weld materials held together under pressure. It can be used to weld both metals and plastics. The ultrasonic vibrations cause coalescence between the materials without melting. It has advantages over other welding techniques like not producing heat, fumes or odors and allowing dissimilar materials to be joined. However, it is limited to lap joints and thin materials due to power limitations. Ultrasonic welding has applications in electronics, appliances, automotive and medical device assembly.

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    Ultrasonic welding is a solid state welding process developed in the 1940s where high-frequency ultrasonic vibrations are used to locally weld materials held together under pressure. It can be used to weld both metals and plastics. The ultrasonic vibrations cause coalescence between the materials without melting. It has advantages over other welding techniques like not producing heat, fumes or odors and allowing dissimilar materials to be joined. However, it is limited to lap joints and thin materials due to power limitations. Ultrasonic welding has applications in electronics, appliances, automotive and medical device assembly.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    559 views25 pages

    Ultrasonic Welding

    Uploaded by

    Shubhangi Ojha
    Ultrasonic welding is a solid state welding process developed in the 1940s where high-frequency ultrasonic vibrations are used to locally weld materials held together under pressure. It can be used to weld both metals and plastics. The ultrasonic vibrations cause coalescence between the materials without melting. It has advantages over other welding techniques like not producing heat, fumes or odors and allowing dissimilar materials to be joined. However, it is limited to lap joints and thin materials due to power limitations. Ultrasonic welding has applications in electronics, appliances, automotive and medical device assembly.

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    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 25

    ULTRASONIC WELDING

    Click to edit Master subtitle style

    SUBMITTED BYSHUBHANGI OJHA ME-3RD YEAR


    7/13/12

    CONTENTS
    q BRIEF HISTORY q INTRODUCTION q CLASSIFICATION q MECHANISM q PROCESS VARIABLES q ADVANTAGES q LIMITATIONS q APPLICATIONS
    7/13/12

    BRIEF HISTORY
    q Ultrasonic welding was first developed

    in the 1940s.

    q But it was used industrially in 1960s. q In 1960 Sonobond

    Ultrasonics,originally known as Aeroprojects, Incorporated, developed the first metal ultrasonic welding machine to be awarded a United States Patent. plastic welding process and it has

    7/13/12 q In 1963 it was introduced into the

    INTRODUCTION
    q What is welding? q What are ultrasonic waves?

    q What is ultrasonic welding?

    7/13/12

    WHAT IS ULTRASONIC q A solidWELDING? state welding process.


    q Wherein high-frequency ultrasonic

    vibrations are locally applied to workpieces being held together under pressure.

    q Which results in coalescence between

    the two pieces to be joined.

    7/13/12

    CLASSIFICATION OF ULTRASONIC OMETAL WELDING Oq Thermoplastics PLASTIC


    WELDING q Mainly non-ferrous
    metals and alloys.
    q Aluminium,copper,ni q Amorphous as

    WELDING well as
    crystalline.

    ckel,molybednum etc.
    q Precious metals like

    platinum,gold,silver etc.

    7/13/12

    ULTRASONIC WELDING COMPONENTS Components of


    ultrasonic welding system include: generator
    q Transducer q Booster q Sonotrode or Horn q Anvil q Pneumatic system
    7/13/12

    q Power supply-sonic

    ULTRASONIC WELDING MECHANISM(METALS q A static clamping ) force is applied


    perpendicular to the interface between the work pieces.
    q The contacting

    sonotrode oscillates parallel to the interface. of static and

    q Combined effect

    7/13/12

    7/13/12

    7/13/12

    ULTRASONIC WELDING MECHANISM(PLASTIC q One of the materials S) usually has a spiked


    energy director which contacts the second plastic part
    q Horn moves to and fro

    vertically.
    q ultrasonic energy

    melts the point contact between the parts, creating a joint.

    7/13/12

    ULTRASONIC WELDING MECHANISM(PLASTIC S)

    7/13/12

    ULTRASONIC WELDING VARIABLES q Ultrasonic power


    q Clamping force q Welding time q Frequency q Linear Vibration Amplitude
    7/13/12

    ULTRASONIC WELDING POWER GENERATION q Frequency is


    transformed to vibration energy through the transducer.
    q Energy requirement

    established through the following empirical relationship. E = K (HT)3/2 E = electrical energy


    7/13/12

    q q

    7/13/12

    7/13/12

    7/13/12

    ADVANTAGES
    qNo heat is applied

    and no melting occurs(METALS) qNo fumes or odour. qDissimilar metals having vastly

    7/13/12

    LIMITATIONS
    q The thickness of the component

    adjacent to the sonotrode tip must not exceed relatively thin gages because of power limitations of the equipment.
    q Process is limited to lap joints. q Butt welds can not be made because

    there is no means of supporting the workpieces and applying clamping force. 7/13/12

    APPLICATIONS
    q Assembling of electronic components

    such as diodes and semiconductors with substrates.


    q Electrical connections to current

    carrying devices including motors, field coils, and capacitors.


    q Encapsulation and packaging. q Plastic parts
    7/13/12

    APPLICATIONS
    q Appliance: steam iron, pump housing,

    vacuum cleaner wand, and dishwasher spray arm. door, instrument cluster, air diverter and mass airflow sensor. switches.

    q Automotive: lenses, filters,valves,glove box

    q Electrical: terminal blocks, connectors, q Medical: arterial filter, cardiometry reservoir,


    7/13/12 blood/gas filter, face mask and IV spike/filter.

    CONCLUSION
    q In conclusion ultrasonic welding has

    many advantages over other welding techniques 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 a relatively small proportion of all of the possible joints. Ultrasonic welding should not be seen as a replacement for other techniques, such as GTAW, 7/13/12 resistance, laser etc; but rather as an option in situations for which it is well

    BIBLIOGRAPHY
    q O.P. Khanna WELDING

    TECHNOLOGY.
    q Staple ultrasonic corporation

    Principles and applications of high grade bonding technology. WELDING TECHNOLOGY.

    q Richard L Little WELDING AND q Internet.


    7/13/12

    THANK YOU
    7/13/12

    QUERIES??? ??
    7/13/12

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