ULTRASONIC WELDING

Ultrasonic Welding
Learning Activities
Lesson Objectives 1. View Slides;
When you finish this lesson you will 2. Read Notes,
understand: 3. Listen to lecture
• Ultrasonic Welding Definition, 4. Do on-line
Characteristics, Process & Applications workbook
• Ultrasonic Power Generation
• Interfacial Interactions & Dissimilar
Metals Welding

Keywords: Ultrasonic Welding, Transducer, Sonotrode, Anvil

 E le c tr ic a l

S o lid
S ta te C h e m ic a l
W e ld in g
F r ic tio n

U lt r o s o n ic
M e c h a n ic a l P re s s u re
W e ld
Definition of Ultrasonic Welding
A solid state welding process in which
coalescence is produced at the faying
surfaces by the application of high
frequency vibratory energy while the
work pieces are held together under
moderately low static pressure.
 Ultrasonic Welding
Process
Clamping
force

Process Mass

Description: wedge Transducer

• Components of
Sonotrode
ultrasonic welding tip

system include: Vibration Weldment

– Transducer Anvil

– Sonotrode Force

– Anvil
 Ultrasonic Welding Mechanism
Clamping
force
• A static clamping force is applied Mass
perpendicular to the interface
between the work pieces.
• The contacting sonotrode oscillates wedge Transducer

parallel to the interface.

• Combined effect of static and Sonotrode
tip
oscillating force produces
deformation which promotes
10-75 KHz workpiece
welding.
Anvil
Force
 Process Variations

• Spot Welding
• Ring Welding
• Line Welding - Linear Sonotrode
• Continuous Seam Welding - Roller Sonotrode
• Microminiature Welding
 Typical 1500 ultrasonic
spot-type welding machine
Courtesy AWS handbook
AWS Welding Handbook
100 W
Lateral Drive
Ultrasonic
Welder

AWS Welding Handbook

Typical Ring Welding Applications
Tip in Shape of Weld AWS Welding Handbook
Attachment for Continuous Ring Welding AWS Welding Handbook
 Tip

Traversing Head for Continuous Seam Welding

AWS Welding Handbook
 Welding Variables

Ultrasonic Welding Variables

• Ultrasonic power
• Clamping force
• Welding time
• Frequency
• Linear Vibration Amplitude
 Power Generation
Ultrasonic Welding Power
Generation
• Electrical power of 60
Hz is supplied to the
frequency converter. Electrical
energy
Frequency
converter

• The frequency

Transducer
converter converts the
required 60 Hz signal
Vibratory
to the welding transducer

frequency (from 10 to
75 kHz).
AWS Welding Handbook
 Power Generation
Ultrasonic Welding Power
Generation
• Frequency is transformed to
vibration energy through the
transducer.
Frequency
• Energy requirement established Electrical
Converter
energy
through the following empirical
relationship.
– E = K (HT)3/2
– E = electrical energy
– H = Vickers hardness number Vibratory
transducer
– T = thickness of the sheet
 Power Requirements

3/2
E = K(HT )

Where:
E = electrical energy, W*s (J)
k = a constant for a given welding system
H = Vickers hardness number of the sheet
T = thickness of the sheet in contact with the sonotrode
tip, in. (mm)
The constant “K” is a complex function that appears to involve primarily
the electromechanical conversion efficiency of the transducer, the
impedance match into the weld, and other characteristics of the welding
system. Different types of transducer systems have substantially different
K values.
Source AWS handbook
AWS Welding Handbook
AWS Welding Handbook
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
 Ultrasonic Welding Interfacial
Interaction
• Localized temperature rises resulting from
interfacial slip and plastic deformation.
• Temperature is also influenced by power, clamping
force, and thermal properties of the material.
• Localized Plastic Deformation
• Metallurgical phenomena such as recrystallizing,
phase transformation, etc..... can occur.
 Ultrasonic Welding Materials Combinations

Source AWS handbook

 Extreme Interpenetration
Nickel Foil (top) to Gold-Plated Kovar Foil

Local Plastic Flow

Dark Regions are Trapped Oxide
Nickel Foil (top) to Molybdenum Sheet

Very Little Penetration, Thin

Bond Line, Fiber Flow
Molybdenum Sheet to Itself

AWS Welding Handbook

Comparison With Resistance Spot Weld AWS Welding Handbook
 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.
• Pressures used are lower, welding times are
shorter, and the thickness of deformed
regions are thinner than for cold welding.
 Limitations of Ultrasonic
Welding
• The thickness of the component adjacent to
the sonotrode tip must not exceed relatively
thin gages because of power limitations of
the equipment.
• Process is limited to lap joints.
• Butt welds can not be made because there is
no means of supporting the workpieces and
applying clamping force.
Other Process Variations
• Ultrasonic Welding of Non-metallic
• Ultrasonic Plastic Welding
Welds Can Be Made to Non-Metallic
Substrate Materials Coated with Thin
Layers of Metal Films

Material Welded
Metal Film
Non-Metallic
AWS Welding Handbook
 Ultrasonic Welding of Plastics

• Advantages
– Fast
– Can spot or seam weld
• Limitations
– Equipment complex,
many variables
– Only use on small parts
– Cannot weld all plastics

0.1.1.2.5.T25.95.12
 Applications of Ultrasonic
Welding
• Assembling of electronic components such
as diodes and semiconductors with
substrates.
• Electrical connections to current carrying
devices including motors, field coils, and
capacitors.
• Encapsulation and packaging.
• Plastic parts
AWS Welding Handbook
Note weld progression (no weld in center) AWS Welding Handbook
Starter motor armature with wires
joined in commutator slots by
ultrasonic welding
Ultrasonically welded Helicopter
access door.
Courtesy AWS handbook
Field coil assembled by ultrasonic welding
Courtesy AWS handbook
AWS Welding Handbook
 Wire Bundle Placed in Jaws
Ultrasonic
Tying Tool

Metal Tape Fed

Around bundle of
Wires and welded
Ultrasonic
once, then cut and
Horn
welded again.

Bundled Wires

Welds

First Weld Made Cut and Second Weld Made

 Ultrasonic Stitch (Clad) Welding

Sonatrode

Anvil

Louks, et al “Ultrasonic Bonding Method” US Patenet 6,099,670 Aug. 8, 2000

 Ultrasonic Welding of Eraser Holder on Plastic Pencil

Coinon, A, Trajber, Z, “Pencil Having and Eraser-Holding

Ferrule Secured by Ultrasonic Welding” US Patent 5,774,931
July 7, 1998
 Explosive Gas Generator For Auto Air Bag
(Plastic Ultrasonic Weld)

Gas Generating
Explosive Powder

Plastic Cap
Primer
Welded to
Plastic Base

Ultrasonic Weld

Avory, et al “Electrical Initiator” US Patent 5,763,814 June 9, 1998.