Madan Mohan Malaviya Univ.

of Technology, Gorakhpur

Ultrasonic Welding Process

CHANDAN KUMAR(2021052004)
MECHANICAL ENGINEERING
Madan Mohan Malviya University of
Technology Gorakhpur (UP State Govt. University)

Email: 2021052004@mmmut.ac.in

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CONTENT
• INTRODUCTION
• HISTORY
• COMPONENTS OF ULTRASONIC WELDING
• ULTRASONIC WELDING MECHANISM
• APPLICATIONS
• ADVANTAGES OF U.S WELDING
• LIMITATIONS OF U.S WELDING
• CONCLUSION
• REFERENCES

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INTRODUCTION

• Ultrasonic welding is an industrial

technique whereby high frequency
ultrasonic acoustic vibrations are
locally applied to work pieces being
held together under pressure to
create a solid-state weld.

• It is commonly used for

plastics,and especially for joining
dissimilar material. In ultrasonic
welding, there are no connective
bolts, nails, Soldering materials or
adhesives necessary to bind the
materials together.
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HISTORY

• Practical applications of ultrasonic welding for rigid plastics was

completed in the 1960s. At this point only hard plastics could be
welded.

• The patent for the ultrasonic method for welding rigid

thermoplastic parts was awarded to robot soloff and seymour
linsley in 1965. Soloff, the founer of sonics & materils inc. was a
lab manager at bronson instruments where thin plastic films were
welded into bags and tubes using ultrasonic probes..

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HISTORY

• He unintentionally moved the probe close to a plastic tape

dispenser and the halves of the dispenser welded together.

• He realized that the probe did not need to be manually moved

around the port but that the ultrasonic energy could travel through
and around rigid plastic and weld on entire joint. He went on to
develop the first ultrasonic press. The first application of this new
technology was in the toy industry

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COMPONENTS OF ULTRASONIC WELDING SYSTEM

• Components of ultrasonic welding

system include:
• Transducer
• Sonotrode
• Anvil

Presented by Mr.Patpitchayut Surote Siam Create

Enterprises Co.,Ltd.

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BASICS OF ULTRASONIC CONCEPT

•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.
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ULTRASONIC WELDING MECHANISM

• A static clamping force is applied
perpendicular to the interface
between the work pieces.
• The contacting Sonotrode
oscillates parallel to the interface.
• Combined effect of static and
oscillating force produces
deformation which promotes
welding.

Presented by Mr.Patpitchayut Surote

Siam Create Enterprises Co.,Ltd.
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How Does Ultrasonic Welding Work

Ultrasonic welding works based on the process of using vibrational sound waves to heat
and melts a material. Below is the summary of how the process works:

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How Does Ultrasonic Welding Work

• Preparation of the material: Arrange the plastic parts to form a lap joint—
afterward, place it on the machine’s welding stack.
• Generation of high-frequency electricity: The machine’s generator will
convert the electricity (50-60 Hz) to high-frequency (20 – 40 kHz).
• Conversion to Ultrasonic: The transducer converts high-frequency
electricity to ultrasonic waves. Afterward, the booster amplifies the
vibration.
• Welding: The welding horn or sonotrode focuses the ultrasonic vibrations
on the arranged plastic or metal parts. The operator then applies pressure
using the press. On completion, the operator retracts the welding horn and
removes the welded materials.

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SCHEMATIC OF AN ULTRASONIC WELDER

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Types of Ultrasonic Welding – Plastics & Metals

• The welding process has a limitation in the types and sizes of materials it is
compatible with. Below are the common materials for this technique.
• · Ultrasonic Plastic Welding
• The ultrasonic welding process is one of the most common plastic welding
techniques. It is suitable for welding thermoplastics such as polycarbonate, ABS,
polyester, etc. However, it would be best if you took note of properties such as the
presence of moisture and hardness. Also, the process is unsuitable for plastic
polymers such as PVC and polyamide.
• · Ultrasonic Metal Welding
• Ultrasonic metal welding technique is compatible with several metals such as
aluminum, copper, silver, brass, nickel, gold, and their alloys. However, the
technique is only suitable for these metals in thin and small dimensions.

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ELEMENTS OF ULTRSONIC WELDING

Sonotrode Booster Converter

Anvil Welding Part

Power Supply Ultrasonic Contrller

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ULTRASONIC WELDING VARIABLES

• Ultrasonic power ( Energy, Ws.)

• Clamping force (Pressure ,Bar)
• Welding time ( Time ,Sec.)
• Frequency (Vibration ,Hz.)
• Linear Vibration Amplitude (Thickness ,mm.)

Presented by Mr.Patpitchayut Surote

Siam Create Enterprises Co.,Ltd.
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ULTRASONIC POWER GENERATION

• Electrical power of 60 Hz is supplied to the

frequency converter.
• The frequency converter converts the
required 60 Hz signal to the welding
frequency (from 10 to 75 kHz).

• Frequency is transformed to vibration

energy through the transducer.
• Energy requirement established through
the following empirical relationship.
• E = K (HT)3/2
• E = electrical energy
• H = Vickers hardness number
• T = thickness of the wall

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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

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ULTRASONIC WELDING MATERIALS COMBINATIONS

Source AWS handbook

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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

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Description of Machine

Main Supply : 230+/- 15% VAC

50/60 Hz. Single Phase / Grounded
Power Consumpation : Max. 3,000 Watt.
Fuse Operation : 16 Amp.
Compressed Air Supply in front of the maintenance unit
: 6.5 – 10 Bar / Dry & Oil Free
Main Air Consumption : approx. 75 L/min. at 6 Bar

Tools
A) Sonotro Safety Fuse A) 2 Amp. B) 12.5 Amp.
de
B) Anvil

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Corrected Insertion of Tube

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APPLICATIONS

• COMPUTER AND ELECTRICAL INDUSTRIES.

• AEROSPACE AND AUTOMOTIVE INDUSTRIES.
• MEDICAL INDUSTRY.
• PACKAGING INDUSTRY

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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
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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.

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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

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CONCLUSION

• Now a day ultrasonic welding is a very useful technique for many

industries.
• This technique is use for both hard and soft plastic and malleable
metal.
• By this process there are many type of design and welding is creating
through small part of plastic.

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REFERENCES

• 1. http://www.wire-cut.co.uk/wireedm.htm
• 2. The History of EDM, retrieved 2010-08-05
• 3. Experience Agie, retrieved 2009-11-02.
• 4. What is wire EDM?, retrieved 2009-11-02.
• 5. Naotake Mohria, Yasushi Fukuzawab, Takayuki Tanic, Nagao Saitoa and
• Katsushi Furutani. Assisting Electrode Method for Machining Insulating
Ceramics. CIRP
• Annals - Manufacturing Technology. Volume 45, Issue 1, 1996, Pages 201-
• 204.doi:10.1016/S0007-8506(07)63047-9
• 8. Willard J. McCarthy, Joseph A. McGeough Machine tool article of the
• Enciclopaedia Britannica URL [1]
• 9. Nonconventional Machining by P K Mishra

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