You are on page 1of 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

You might also like