Professional Documents
Culture Documents
1/2010
CERCETRI EXPERIMENTALE
EXPERIMENTAL RESEARCH ON
PRIVIND SUDAREA CU
ULTRASONIC WELDING
ULTRASUNETE A COMBINAIILOR
OF MATERIAL COMBINATIONS AL -
DE MATERIALE AL -AL
AL
Keywords:Ultrasounds,
Aluminum
1. Consideraii teoretice
Sudarea cu ultrasunete a materialelor
metalice face parte din procedeele de sudare
prin presiune n stare solid. Energia necesar
sudrii se introduce n componentele de sudat,
prin provocarea unor vibraii n locul
mbinrii, cu o frecven corespunztoare
ultrasunetelor
(161031010
Hz),
componentele de sudat fiind presate cu o for
normal pe suprafaa lor de contact.
Prin aciunea simultan a vibraiilor i
forei de apsare se produc tensiuni oscilante
n zonele vecine celei de contact. Acestea
conduc la alunecri si frecri ntre cele dou
componente de sudat, la expulzarea oxizilor i
1. Theoretical Considerations
Ultrasonic welding of metallic materials
is part of the processes of welding pressure in
solid shape. Energy required for welding is
introduced in welded components, the
challenge of combining vibrations instead,
with
an
appropriate
frequency
3
10
ultrasound(1610 10
Hz),
welded
components are pressed with a normal force
on their surface contact.
The simultaneous action of vibration and
pressing force producing oscillating tension
in the neighboring areas of contactless. This
leads to slip and friction between the two
components soldered, to expel oxides and
Optimum
tehnology,
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F=
1 n
Fi
n i =1
(1)
- dispersia corectat s-2, cu relaia:
2
s =
1 n
( Fi F ) 2
n 1 i =1
F=
1 n
Fi
n i =1
(1)
- the corrected dispersion
2
s =
, with:
1 n
( Fi F ) 2
n 1 i =1
(2)
(2)
- abaterea medie ptratic corectat s , cu
- the corrected medium square deviation
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relatia:
s=
, with:
2
1 n
( Fi F )
n 1 i =1
s=
(3)
- coeficientul de variaie W, cu relaia:
W =
2
1 n
( Fi F )
n 1 i =1
(3)
- the variation coefficient W, with:
s
100 0 0
F
W =
s
100 0 0
F
(4)
n care: Fi este rezultatul unei msurtori; n
(4)
numrul de experiene (suduri);
where: is the tested value ; n- number
Pentru excluderea rezultatelor rebut se of measurements
foloseste criteriul student:
To exclud the result of a reject we use the
student criterion:
Fj F
t=
Fj F
s
t=
(5)
s
n care: F j este valoarea testat (cea mai
mare sau cea mai mic din cele n (5)
where: is the tested value (the highest
msurtori); F - valoarea medie a forei de
or the lowest in the n measurements); - the
rupere la traciune.
Pentru verificarea ipotezei c dou medium value of the traction break force.
To verify the hypothesis that two random
valori medii oarecare F1 si F2
aparin
medium values and
belong to the same
aceleai valori reale se folosete mai ntai
real value, first the F test is used:
testulF, de forma:
F = s12 /s 22
(6)
i apoi testul t, de forma:
F = s12 /s 22
(6)
and then the t test,under the form :
n1 n 2
n1 + n 2
(7)
(7)
where: ,
are the studied medium
n care: F1 ; F2 sunt valorile medii studiate;
values; ; the number of experiments
n1;n2 - numrul de experiene din care s-au
where
were determined;
- the
determinat F1 , ; F2 ; s - abaterea medie corrected
medium
square
deviation,
ptratic corectat, calculat dupa formula:
calculated as such:
t=
F1 F 2
s
s=
n1 n 2
n1 + n 2
t=
f 1 s12 + f 2 s 22
f
s=
(8)
F1 F 2
s
f 1 s12 + f 2 s 22
f
(8)
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n care:
f1=n1-1; f2=n2-1; f=f1+f2=n1+n2-2 sunt gradele
de libertate respective.
2. Experimental Results
The conditions for welding realization
are
the fallowing: power 860W for
aluminum ; pressing force adjustable between
175.2050N ; welding time adjustable
between
0,55,5s;
tool
oscillation
amplitude: 6,411,8 m; frequency:
2,16104 Hz; tool and anvil with flat and
rough surface; direction of oscillation of the
tool: perpendicular to the direction of rolling;
surface state components: degreased in
trichloroethylene.
In all situations the welding resistance
was over 85% from the base material
resistance. From speciallity documents results
that welded joints quality is not influenced
just by welding parameters, also by a series
of technological factors:the tool and anvil
geometry,the tool oscillation direction
compared with rolling direction.
For studing the tool geometrical influency
about welded joint quality are chosen
different types of tools(fig.1,a ) made from
stelit with hardness 50-55 HRC and
roughness Ra = 1,5 10-3 mm. In figure 1,b
are represented different geometry for used
anvils.
In first stage of experience its settled the best
geometry. For this it used the tool A and the
four anvils N1,N2,N3 and N4 . from the
beginning its seems that anvil N4 are not
good because its very smooth is produced
the sliding of the inferior board on her.
30
60
O 5 ,2
O 5 ,2
O 9
0,6
O 9
0,6
O 9
0,6
O 9
R1
0,6
O 9
0,6
2. Rezultate experimentale:
Condiiile n care s-au realizat sudurile
sunt urmtoarele: puterea: 860W pentru
aluminiu; fora de apsare: reglabil n limitele
1752050 N; timpul de sudare reglabil n
limitele 0,55,5s; amplitudinea de oscilaie a
sculei: 6,411,8 m; frecvena: 2,16104 Hz;
scula i nicovala cu suprafee plane i rugoase;
direcia de oscilaie a sculei: perpendicular pe
direcia de laminare; starea suprafeelor
componentelor: degresate n tricloretilen.
In toate situatiile rezistenta sudurii a fost
peste 85% din rezistenta materialului de baz.
Din literatura de specialitate rezult c asupra
calittii imbinrilor sudate influenteaz nu
numai parametrii regimului de sudare ci si o
serie de factori tehnologici: geometria sculei si
a nicovalei, directia de oscilare a sculei in
raport cu directia de laminare.
Pentru studierea influentei geometriei
sculei asupra calittii imbinrii sudate s-au
ales diferite tipuri de scule (fig. 1, a), executate
din stelit cu duritatea 50-55HRC si rugozitatea
Ra = 1,5 10-3 mm. In figura 1, b sunt
reprezentate diferite geometrii pentru
nicovalele utilizate.
O 5 ,2
O 5 ,2
O 3
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3 ,2
0 ,8
O 35
O 35
O 35
O 35
950
Timpul
de
sudare
t[s]
Nicovala
N1
N2
N3
Forta de rupere la
forfecare Fs [N]
1,0
642
677
653
3,0
665
822
4,0
688
5,5
Forta
de
apsare
P [N]
1550
Timpul
de
sudare
t[s]
Nicovala
N1
N2
N3
Forta de rupere la
forfecare Fs [N]
1,0
705
735
720
707
3,0
730
785
827
878
745
4,0
642
835
817
773
880
867
5,5
687
867
817
1,0
730
730
727
1,0
730
753
753
3,0
727
848
742
3,0
758
780
860
4,0
783
863
760
4,0
633
800
853
5,5
790
885
816
5,5
607
838
772
2050
950
Anvil
N1
N2
N3
1,0
642
677
653
3,0
665
822
4,0
688
5,5
1,0
Pressing Welding
time
force
t[s]
P [N]
1550
Anvil
N1
N2
N3
1,0
705
735
720
707
3,0
730
785
827
878
745
4,0
642
835
817
773
880
867
5,5
687
867
817
730
730
727
1,0
730
753
753
2050
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3,0
727
848
742
3,0
758
780
860
4,0
783
863
760
4,0
633
800
853
5,5
790
885
816
5,5
607
838
772
850
Forta de tractine F [N]
850
750
650
550
0
P = 390 N
Nicovala N 1
Nicovala N 2
Nicovala N 3
4
Timpul de sudare t[s]
750
650
550
0
P = 950 N
Nicovala N 1
Nicovala N 2
Nicovala N 3
4
Timpul de sudare t[s]
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850
Forta de tractine F [N]
850
750
650
550
0
400
800
t = 3[s] (6,48 10 z)
Nicovala N 1
Nicovala N 2
Nicovala N 3
1200
1600
2000
Forta de presare P [N]
650
550
0
t = 4[s] (8,46 10 4 z)
Nicovala N 1
Nicovala N 2
Nicovala N 3
400
800
1200
1600
2000
Forta de presare P [N]
850
850
Forta de tractine F [N]
750
750
650
P =390 N
Nicovala N2
550
0
Scula A
Scula B
Scula C
Scula D
4
Timpul de sudare t[s]
750
650
P=950 N
Nicovala N2
550
0
Scula A
Scula B
Scula C
Scula D
4
Timpul de sudare t[s]
850
850
750
650
550
0
t = 3s
Nicovala N 2
Scula A
Scula B
Scula C
Scula D
400
800
1200
1600
Forta de presare P[N]
2000
650
550
0
750
t = 4s
Nicovala N 2
400
800
1200
1600
Forta de presare P[N]
Scula A
Scula B
Scula C
Scula D
2000
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Forta de
apasare
Fp [N]
k1
k2
950
k3
k4
Timpul de Forta de
rupere la
sudare
forfecare
t[s]
Fs [N]
0,5
1,0
3,0
650
665
745
0,5
1,0
3,0
490
570
665
0,5
1,0
3,0
570
590
652
0,5
1,0
3,0
530
545
600
100x
800x
800x
Fig. 10. Microfotografia imbinrii / welded joints micro photos:
a - K2, t = 3 s; b - K1, t = 3 s ; c - K2, t = 1 s
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800x
800x
800x
Fig. 11 Microstructura imbinarii:
a aluminiu-aluminiu, t= 1s; b - aluminiu-aluminiu, t= 2s; c - aluminiu-aluminiu, t= 3s
Fig. 15. welded joints micro structure:
a - aluminum- aluminum , t=1s; b aluminum- aluminum, t=2s; c aluminum- aluminum, t=3s.
3. Concluzii
La sudarea cu ultrasunete a
materialelor metalice, vibratiile produse de
transductorul magnetostrictiv si amplificate de
concentratoarele acustice sunt transmise la
locul mbinrii intr-un plan paralel cu
suprafata de contact. Prin actiunea simultan a
vibratiilor si a fortei de apsare se produc
tensiuni oscilante in zonele vecine celei de
contact. Acestea conduc la alunecri ntre cele
dou componente de sudat la expulzarea
oxizilor si impurittilor de pe suprafetele in
contact, urmnd astfel realizarea legturilor
metalice a celor dou componente;
Asupra calittii imbinrii sudate cu
3. Conclusions
On ultrasonic welding of metallic
materials , vibrations produced by
magnetostrictive transducer and amplified by
acoustic concentrators are transmitted at the
join by a parallel plan with the contact
surface. The simultaneous action of vibration
and pressing force is producing oscillating
tension in areas neighboring the contact. This
leads to sliding between the two welded
components at the expel of the oxides and
impurities from the surfaces in contact,
following such the achievement of metal
connections of the two components;
On ultrasonic welded joint quality acts
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ultrasunete
actioneaz
att
parametrii
principali ai regimului de sudare (amplitudine
de oscilatie a sculei (325)*10-3 mm, forta
specific de apsare (40120MPa), frecventa
de oscilatie (1825)*103 Hz, timpul de
sudare (0,053)s , ct si factorii tehnologici
(geometria sculei si ai nicovalei, materialul din
care se face sistemul oscilant, componentele
de sudat si directia de oscilatie a sculei in
raport cu directia de laminare a tablelor;
Aproape toate materialele i aliajele
metalice se pot suda cu ultrasunete, dar nu
intotdeauna procedeul este cel mai economic.
In fiecare caz n parte, parametrii optimi de
sudare
se
stabilesc
pe
cale
experimental;Procedeul de sudare cu
ultrasunete se aplic deja pe cale industrial n
industria electrotehnic i electronic la
fabricarea componentelor miniaturizate i
ultraminiaturizate, a diferitelor tipuri de
contacte electrice i a produselor din aluminiu,
mai ales dac ele se compun din folii. Se
sudeaz bine componentele conductoare de
curent electric din diferite materiale (aluminiu,
cupru, argint), precum i srme subiri
calibrate , cu rezitena electric ridicat.
Bibliografie:
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