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ULTRASONIC WELDING PDF

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Compared with other welding methods – which include heat staking, hot plate welding, spin welding, and vibration welding – ultrasonic welding offers. 𝗣𝗗𝗙 | On Mar 1, , Frank Balle and others published Ultrasonic Welding. Fundamentals of the. Ultrasonic Plastics Welding. Leo Klinstein. Dukane IAS. St. Charles, IL [email protected] UIA San Francisco April 17th.


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The motorized feed allows different conductors and compaction lengths to be processed in a sequence without changeover. The process parameters can be set. Ultrasonic metal welding Eindhoven: Technische Hogeschool Publisher's PDF, also known as Version of Record (includes final page, issue. Ultrasonic welding is an industrial technique whereby high- frequency ultrasonic acoustic vibrations are locally applied to work pieces being.

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Start on. Show related SlideShares at end. Working Process of Ultrasonic Welding The two plastic pieces to be joined is assembled in the nest anvil or fixture The horn is made to contact at upper part of the piece.

A pressure is applied on the two pieces against the fixture. The pressure is applied through the pneumatic or electric driven press. Horn is vibrated vertically at very high frequency 20 kHz to 40 kHz , transmits the mechanical vibration to the two plastic pieces. This generates heat energy at contact tip of the two surfaces and melts them.

Ultrasonic Welding : Principle, Working, Equipment’s, Application, Advantages and Disadvantages

A clamping force is applied on the two pieces for a predetermined amount of time to fuse them together to form a strong weld on cooling and solidification. After solidification, the clamping force is removed and horn retracted.

The welded plastic part is taken out of the fixture as one piece. Application It is mostly used in computer and electrical, aerospace and automotive, medical, and packaging industries. Computer and Electrical Industries: Here it is used to join wired connections and to create connections in small delicate circuits.

Aerospace and Automotive Industry In automotive industries it is used to assemble large plastic and electrical components such as door panels, instrument panels, air ducts, lamps, steering wheels, and upholstery and engine components.

In aerospace it is used to join thin sheet gauge and lightweight materials like aluminum. Medical Industry It does not introduce any contaminants or degradation into the weld. Packaging Industry It is used to package different materials in food industries.

It is used for packaging dangerous materials like explosives, fireworks and chemical. Ultrasonic welding continues to be a rapidly developing field. Scientists from the Institute of Materials Science and Engineering WKK of University of Kaiserslautern, with the support from the German Research Foundation Deutsche Forschungsgemeinschaft , have succeeded in proving that using ultrasonic welding processes can lead to highly durable bonds between light metals and Carbon-fiber-reinforced polymer CFRP sheets.

The drying time is very quick, and the pieces do not need to remain in a fixture for long periods of time waiting for the joint to dry or cure. The welding can easily be automated, making clean and precise joints; the site of the weld is very clean and rarely requires any touch-up work.

The low thermal impact on the materials involved enables a greater number of materials to be welded together. All ultrasonic welding systems are composed of the same basic elements: A press, usually with a pneumatic or electric drive, to assemble two parts under pressure A nest or anvil or fixture where the parts are placed and allowing the high frequency vibration to be directed to the interfaces An ultrasonic stack composed of a converter or piezoelectric transducer , an optional booster and a sonotrode US: Horn.

It is also used in standard systems to clamp the stack in the press. Horn or Sonotrode: Take the shape of the part, also modifies the amplitude mechanically and Applies the mechanical vibration to the parts to be welded. An electronic ultrasonic generator US: Power supply delivering a high power electric signal with frequency matching the resonance frequency of the stack. A controller controlling the movement of the press and the delivery of the ultrasonic energy.

Applications[ edit ] The applications of ultrasonic welding are extensive and are found in many industries including electrical and computer, automotive and aerospace, medical, and packaging.

Ultrasonic Welding : Principle, Working, Equipment’s, Application, Advantages and Disadvantages

Whether two items can be ultrasonically welded is determined by their thickness. If they are too thick this process will not join them. This is the main obstacle in the welding of metals.

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However, wires, microcircuit connections, sheet metal, foils, ribbons and meshes are often joined using ultrasonic welding. Ultrasonic welding is a very popular technique for bonding thermoplastics. It is fast and easily automated with weld times often below one second and there is no ventilation system required to remove heat or exhaust.

This type of welding is often used to build assemblies that are too small, too complex, or too delicate for more common welding techniques. Computer and electrical industries[ edit ] In the electrical and computer industry ultrasonic welding is often used to join wired connections and to create connections in small, delicate circuits.

Junctions of wire harnesses are often joined using ultrasonic welding.

Main Parts

Electric motors , field coils , transformers and capacitors may also be assembled with ultrasonic welding. Semiconductor devices, transistors and diodes are often connected by thin aluminum and gold wires using ultrasonic welding. An example of where microcircuits are used is in medical sensors used to monitor the human heart in bypass patients. One difference between ultrasonic welding and traditional welding is the ability of ultrasonic welding to join dissimilar materials.

The assembly of battery components is a good example of where this ability is utilized.

Working Principle

When creating battery and fuel cell components, thin gauge copper, nickel and aluminium connections, foil layers and metal meshes are often ultrasonically welded together.The second part of contamination is in the form of ordinary dirt and oils.

Here in amplitude has significant effect on the response weld the USW, the controlled factors are welding time, welding strength. However, for the both types of specimen tested ultrasonic metal welding machine 2,W, 20kHz for Mode I and II the optimum joint strength was found to different ranges of weld parameters.

Ultrasonic welding process is restricted to the lap joints. The ultrasonic welding needs high frequency and high voltage power supply. This vibration further supplied to the booster which amplify its frequency.

Ultrasonic welding

The high frequency vibration generates heat energy at the interface of the two pieces and melts the material. Ultrasonic welding is also applied in the packaging of dangerous materials, such as explosives, fireworks and other reactive chemicals. These impurities form a layer that prevents the electrons in the two parts from passing between them, thus preventing them from welding together. Here a.

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