MINI PROJECT REPORT

ON
ULTRASONIC WELDING

TEJASWI KUMAR (2102018D)

SUMIT SHEKHAR (2102011D)
SHASHIKANT (2102017D)

––

DEPARTMENT OF PRODUCTION AN
INDUSTRIAL
ENGINEERING
BIT, SINDRI, DHANBAD, JHARKHAND
2023-24

UNDER THE GUIDANCE OF PROF. S.N.

PANDA
ULTRASONIC WELDING : A REVIEW

ABSTRACT

Ultrasonic welding is proven as the popular welding method in plastic

industries for joining purpose since 1963. Ultrasonic welding is one of the most
popular welding techniques used in the welding industry. It is fast, economical,
easily automated, and well suited for mass production, with production rates up
to 60 parts per minute being possible. The specimens used in this process,
ultrasonic welding are aluminium sheets. These sheets have dimension of 80
mm length, 20 mm width, and 0.56 mm thickness. Before ultrasonic welding of
these sheets, those are cleaned with acetone as if any impurity will be found on
sheets they can affect bond strength. This study is focused on joining of the
metal sheets (aluminium & aluminium sheet) using ultrasonic welding
technique. The variables are weld time, weld pressure, amplitude. Additionally,
this paper provides different examples and applications of ultrasonic welding
technique and its application. Main advantages of this technique are, clean
and undamaged exterior parts of weld, power savings, stable and strong bond,
time efficiency.

INTRODUCTION
Development of new welding process is required for joining of plastic material and dissimilar
material. Ultrasonic spot welding (USW) is a potential means of joining thin, multiple, soft,
and conductive metals such as aluminium , copper, brass, magnesium, nickel, steel, and
titanium. Ultrasonic welding is proven as the popular welding method in plastic industries for
joining purpose since 1963. Ultrasonic welding is one of the most popular welding
techniques used in the welding industry. It is fast, economical, easily automated, and well
suited for mass production, with production rates up to 60 parts per minute being possible.
The ultrasonic welding process has short welding time in less than one second. Ultrasonic
welding is solid state welding and uses no filler material so called Autogenous welding. This
welding process does not uses any flux and it does not required External heat source.
Ultrasonic welding method uses high frequency around 20khz-60khz and pressure through
clamping of plates. Ultrasonic welding is used for applications involving both similar and
dissimilar joints as well as the welding of polymers. The process is used to produce lap joints
in metals, plastic sheets and plastic films in varied shapes as wires (crossed or parallel),
ribbons and flat surfaces.

EROL SANCAKTA(1)discusses the weldability of similar and dissimilar thermoplastics

with the use of ultrasonic welding and compares the experimental results with those obtained
previously by using the heated tool method. Ultrasonic spot welding was used to join a low
rare-earth containing ZEK100 Mg alloy at different levels of welding energy, and tensile lap
shear tests were conducted to evaluate the failure strength in relation to the microstructural
changes (2) . Qian Zhi1(3) studied the weldability of single-sided ultrasonic welding of 4-
mm-thick carbon fibre/Nylon 66 composite was studied. Extensive welding was performed,
and the weld microstructures, fractographies, and appearances of welded joints were
examined and analysed. Lei Xiu1 (4) The ultrasonic impact method to remove welding
residual stress, which is to use ultrasonic impact equipment for high speed impact weld and
near weld zone, the metal in the region can produce plastic deformation. Z. L. Ni &(5)
discussed Joint of aluminium to copper sheets with an Al2219 particle interlayer was
successfully achieved by the ultrasonic spot welding (USW). Effects of clamping pressure
and surface activation on the microstructure and mechanical performances of the joints were
systematically studied. A central research field of the Institute of Materials Science and
Engineering at the University of Kaiserslautern (WKK), Germany, is the realization of
innovative hybrid joints by ultrasonic metal welding. This article gives an overview of
suitable ultrasonic welding systems as well as of essential machine and material parameters,
which influence the quality of the welds. Besides the ultrasonic welding of dissimilar metals
such as Al to Cu or Al to steels, the welds between newly developed materials like
aluminium foam sandwiches or flat flexible cables also can be realized(6). G. TONDI(7)
Two alternative welding systems were evaluated for wood welding. Ultrasonic welding
produces joints of good strength but it appears to be applicable only to thin wood pieces. It
does not appear that further possible process improvement could bring the joint strength to a
structural level. Microfriction stir welding does show potential for welding continuously
wooden plates without any limitation on length of wood pieces. The ultrasonic welding
process, a solid-state joining method, using the example of welding of a magnesium alloy as
well as the joining of magnesium alloys in general. In situ high-speed imaging and infrared
thermography were utilized to study interfacial relative motion and heat generation during
ultrasonic spot welding of AZ31B magnesium (Mg) alloys(8). Joining of lightweight
dissimilar materials becomes increasingly important, especially for structural applications
and transportation industries to reduce the weight and thus decrease the fuel consumption and
CO2 emissions. Previously, the joining of lightweight materials (metals and polymers) has
been performed using mechanical fastenings, such as screws, bolts, and rivets, or adhesion
techniques. However, the disadvantages of these mechanical methods are considerable stress
concentration around the fastener hole, the potential in the corrosion problems, and potential
in fatigue cracking in metallic materials(9). A method has been developed allowing
fabrication of electronic boards from flexible polymer film by ultrasonic embossing and
welding within seconds(10). Effect of ultrasonic vibrations on friction stir welding (FSW) is
studied. Ultrasonic vibrations were employed on the tool in pin direction (perpendicular to
the welding direction). To do this study, a vibration tool was designed by Abaqus software in
a way to have a longitudinal frequency about 20 kHz and was then manufactured and
assembled with an ultrasonic transducer and was controlled using an ultrasonic generator to
oscillate ultrasonically with a peak-to-peak amplitude of 10 μm(11). Ultrasonic-assisted laser
welding on 321 stainless steel has been carried out to find out the effect of ultrasonic energy
input on the microstructure and strength of the weld metal. Ultrasonic energy was transmitted
from a transducer, via two waveguides and hard alloy indenter fixed perpendicularly on the
workpiece surface(12).

As explained, there is a growing call from industries to come with a faster and effective way
of joining composite structures. In this paper, a detailed literature review is carried out
regarding the fusion joining process, ultrasonic welding for composites. The advantages of
using ultrasonic welding over conventional and other fusion joining methods and its
applications are also deliberated. The important features and the physical parameters deemed
important for the ultrasonic welding machine are discussed in detail. The different process
parameters that influence the welding quality and other welding aspects for welding TP to TP
composites and TP to TS and other materials, are explained in the subsequent sections. A
detailed review covering the ultrasonic welding of different TP material systems, and novel
attempts to join dissimilar materials, is presented, which could be of significant interest for a
scientific and industrial community to refer to. The future directions based on the research
gap in the area of ultrasonic welding technology is also discussed in the final section of the
paper.

DIFFERENT JOINING PROCESSES

Most manufacturing processes include some series of operations to produce
components having different physical, mechanical, chemical, and dimensional
properties. Manufacturing large composite parts, such as the fuselage and wing
section of aircraft, or the body of the automobile car, require a large and complex
mold, which consequently means a substantial increase in the cost. However, such a
complex part can be manufactured through the assembling of small parts by using
different joining techniques. There are several joining methods [13] used for
composite materials, as shown in Figure 1. For assembling the large composite
structures, the conventional methods which are used in industries are mechanical
fastening using rivets and bolts, co‐consolidation bonding, and chemical bonding by
control adhesives [14].

For assembling the large composite structures, the conventional methods which are
used in industries are mechanical fastening using rivets and bolts, co ‐consolidation
bonding, and chemical bonding by control adhesives [15].
FUSION WELDING TECHNIQUE AND ISSUE

Fusion welding techniques involve the melting of mating surfaces of the base material as
well as the filler materials to form weld beads. Thus, heat is an essential component in this
process, and it can be supplied from outside in forms of electric arc, gas, resistance heat, and
laser beam [2]. Although there are certain advantages of these processes, some factors really
make it a challenging task, especially in the case of joining of dissimilar metals. These issues
include the generation of residual stress, distortion, and a heat-affected zone (HAZ).
Moreover, the mechanical characteristics of the base metal are also severely FIGURE 1.1
Basic classification of joining techniques among various manufacturing processes.
Introduction 3 affected by this strong heating. During the resistance spot welding (RSW)
process, some amount of contact pressure (along with the electric resistance) is required to
produce coalescence at the faying surface. RSW is widely used in the automobile, heavy
engineering, and electronics sectors due to its fast, automated, and reliable nature. However,
this technique encounters many hurdles during the welding of materials of high electrical and
thermal conductivities with dissimilar properties [16]. Moreover, the process requires high
energy (i.e., 50–100 kilojoules [kJ] per single weld spot) [17]. This process is more prone to
form intermetallic compounds during the welding process; create a large HAZ; and suffer
distortion, cracks, residual stress, and short electrode life. FIGURE 1.2 portrays a typical
interface failure in RSW.
SOLID STATE WELDING TECHNIQUE AND ISSUE

Solid‐state welding is a kind of process in which the faying surfaces of the base material get
joined without melting. Pressure must be applied to get a good joint by forming a thick
metallic bond between the workpieces. It is worth noting that the temperature involved in all
solid-state welding techniques is below the melting point of the base materials. This
technique utilizes the combination of heat and pressure for a particular time period to
overcome hurdles such as porosity, cracks, and slag inclusions faced by the conventional
welding process. Solid-state welding includes the pressure, forge, friction, explosive,
diffusion, and ultrasonic welding processes. The basic principle of these processes is the
atomic diffusion between the two materials, which will occur when the interatomic distance
is below 10 Å. Thus, these types of welding methods require clean and perfectly smooth
surfaces. The major hindrances of these techniques are the formation of an oxide layer and
the presence of oils and other contaminants. These factors make the solid-state welding
process a little more complicated than other welding methods. However, the distinct
advantages of solid-state welding techniques include no requirement for filler material; lower
value of residual stress, distortion, and HAZ; and no change in the mechanical properties of
the base material. However, the expensive equipment, long specimen preparation time,
complicated joint design, and nonconductive properties of the material limit the use of this
technique in many cases.

USW typically requires less than 0.5 seconds weld cycle time and produces higher-quality
and stronger joints in comparison with FSSW technique on the basis of the same weld nugget
area.

ULTRASONIC WELDING TECHNIQUE

The ultrasonic welding technology is widely used as a joining technique in industries. It was
invented in the 1950s, and is used to join metal, nonmetals, and most recently, the polymer
matrix composites.

Ultrasonic welding falls under the frictional welding category. It is an ultrafast process of
joining thermoplastic composites and works on the principle of an application of the high
frequency and low amplitude vibration at the interface of the joining surfaces of the
adherends to be welded.  Ultrasonic welding possesses distinct advantages over other fusion
bonding methodologies, such that the high weld strength can be obtained, welding can be
completed in a few seconds, and it is independent of using a particular material at the
interface, as required in resistance and other welding methods.

Therefore, ultrasonic welding is getting wide attention in many industrial applications, such
as the joining of TP composite parts in the aerospace and automotive industries, wire binding
in electronics, and in the packaging industry for sealing purposes.

Ultrasonic welding incorporates the usage of very high‐frequency (commonly 20 kHz), and
frictional heat is generated at the interface due to the transmission of mechanical vibrations
transmitted through thermoplastic adherends. It helps the thermoplastic material to melt and
flow and form the interfacial bond between them. The main heating mechanisms are
viscoelastic friction and surface friction. It is deduced from these studies that the interfacial
friction is the cause for the initial start of the welding process. Whereas, the viscoelastic
heating dominates after the glass transition temperature of the polymer has reached, and it
provides the maximum heating during the welding process.

Many researchers have studied the applications of ultrasonic welding technology, and
explained the advantages and the drawbacks of using this process for thermoplastic
composites. There are many benefits of using the ultrasonic welding technique, as discussed
below:   

 Ultrasonic welding is one of the fastest joining methods as compared to other techniques,
such as induction,resistance welding and arc welding, and hence is most suitable for mass
production and automated processes .

 No foreign substances such as fillers are required for the ultrasonic welding of specimens.
Spot or seam welding can be carried out using this method.

 The surface damage is minimal in ultrasonic welding, as heat is generated at the interface
rather than the top of the surface like in other welding processes, such as friction stir
welding.

 It is a clean joining process, as it does not generate fumes or sparks during welding, and
thus, is considered environmentally friendly .

Applications of Ultrasonic Welding

Ultrasonic welding has numerous applications in varied industrial fields. These can be found
in automotive, aerospace, medical, electronic and electrical applications and many others . In
aerospace and automotive industries, they require a lightweight material to increase
efficiency by reducing energy consumption. Hence, using a fastener or bolted joint will add
the weight, and due to the long curing cycle of adhesive joints, ultrasonic welding is the
preferred option for mass production in industries [18]. As mentioned by Palardy et al.,
ultrasonic welding can be scaled up by sequential welding; i.e. a continuous line of spot
welding will serve the same effect of a continuous weld [19]. Thus, ultrasonic welding can be
used for applications where a longer part is needed to be welded. Being a cleaner process as
compared to others, and there is no contamination, ultrasonic welding is preferred in medical
applications such as hospital wear, medical chip tests, sterile clothing, masks and textiles that
are used in clean rooms [20]. Nowadays, this technique is also used in the packaging
industries for the packing of items like milk containers; these containers are made from glass,
and are sealed with aluminum foil [21]. Furthermore, in electronic industries, it is used to
assemble the electronic parts, such as diodes and semiconductors, with substrates. Also,
electrical connections between the devices, such as motors, field coils and capacitors, can be
connected using ultrasonic welding, for which the traditional fastening and adhesives are not
desirable .

SOME DRAWBACKS OF ULTRASONIC WELDING PROCESS

 The ultrasonic process is limited to the overlap and shear joints and to the maximum
thickness it can weld. As it is difficult for the vibration to penetrate through the thicker parts
and the oscillation in the bonding zone, it is not enough to produce a sound quality weld [22].
Currently, the thickness is limited to around 3 mm, due to the power of the equipment being
specified [23].

 While using the ultrasonic welding process, the effects of some of the material properties
are unavoidable. High stiffness, hardness and the damping factor being the material
properties, affect the basis of the ultrasonic technique, which is to convert the vibration into
thermal energy. These material properties change the amount of vibration energy required to
be delivered to the interface [24].

 Ultrasonic welding works on the principle of mechanical vibration transmission, so audible

noise may be produced from the resonance state, and is inevitable. In addition, due to
vibrational cyclic loading, the chances of the specimen to fail in fatigue are more [25].

Ultrasonic welding equipment is used to transmit mechanical vibration at high frequency to

the joint interface along with a static compressive force. Due to the simultaneous application
of static force and dynamic vibrations, fusion at the interface between the specimen occurs,
thereby resulting in a weld. There are five main components in the ultrasonic welding
machine, such as an ultrasonic generator, a transducer (converter), booster, sonotrode (horn)
and the fixture on which specimens rest.

Ultrasonic Generator

The main function of an ultrasonic generator is to convert electrical power (5000 W (watts))
at 50–60 Hz into electrical energy at a high frequency of 20 to 40 kHz. The widely used
frequency for ultrasonic welding applications is 20 kHz.
Transducer

A transducer (converter) functions to convert high‐frequency electrical pulses produced from

the generator into the mechanical vibrations, and to facilitate this, piezoceramics are used,
which expand and contract on exposure to an alternating voltage.

Booster

As the name suggests, after obtaining the mechanical vibration from the transducer, a booster
is used to increase or decrease the amplitude of vibrations as per the design requirement by
adjusting the geometry.

Sonotrode

The main component which will directly encounter the specimen is the sonotrode (horn). The
function of the sonotrode is to transfer mechanical oscillations to the specimens to be welded.
They can be of different designs and geometries to deliver the right/optimum vibrations to
the workpiece. This sonotrode is mostly made up of titanium and aluminum and their
selection is heavily dependent on the application and possible cost constraints.

Fixture

The fixture is the component placed below the specimen. The main function of the fixture is
to hold the specimen in place during the welding process to facilitate a sound bonding. In
addition to these five components, an ultrasonic welding machine requires many other
components, e.g. mainframe or structure to hold all components together, air compressor, and

plc (programmable logic controller) to control the variable parameters.

CLASSIFICATION OF ULTRAONIC WELDING PROCESS

Two major types of ultrasonic welding machines are 1. Ultrasonic plastic welding machine
(USPW) 2. Ultrasonic metal welding machine (USMW).

The two different types of ultrasonic welding is shown in fig 1.

Types of Ultrasonic welding: (a) Ultrasonic Plastic welding, (b) Ultrasonic metal welding.

Near Field Weld (Direct): Refers to a weld where the contact surface of the horn is 1/4" or
less away from the joint surface.

It is important that the horn fits exactly the contour of the part to be welded.

Far Field Weld (Indirect): The distance between the contact surface of the horn and weld
between the contact surface of the horn and weld joint is more the 1/4".

Ultrasonic energy is transmitted through the upper portion of the part to the joint surface.
 Fig 2. Represents types of ultrasonic
welding process based upon contact.

EXPERIMENTAL WORK

The specimens[29] used in this process, ultrasonic welding are aluminium sheets. These
sheets have dimension of 80 mm length, 20 mm width, and 0.56 mm thickness. Before
ultrasonic welding of these sheets, those are cleaned with acetone as if any impurity will be
found on sheets they can affect bond strength.[26,27,28]

Aluminum

Researchers state that, “aluminum comprises 8% of the earth’s crust and is, therefore the
most abundant structural metal” [26]. Its production is higher than that of copper, and second
compared to iron. Initially its unit price was very high which steadily decreased with new
smelting technologies. Today the price of aluminum is lower than the price of copper.
Because of its electrical properties it is competing with copper in the electric and
construction industry. Although the electrical conductivity of aluminum is slightly lower than
that of copper, it is preferred over copper in power cables because of its lighter weight.
Aluminum used in the industry can be anodized to produce a protective oxide film, which
can be dyed to give a colorful appearance. The anodizing process uses a bath of dilute
sulfuric acid as an electrolyte and charging the piece electrically. The piece that is being
anodized is the anode –the positive pole -- and the electrolyte becomes the negative pole –the
cathode. The electrical charge and the mild acid oxidize the aluminum surface, leading to
microscopic crystals of aluminum oxide, which is very hard, but very porous. This porosity is
responsible for absorbing and holding the colors of the dye. After the anodized part is
removed from the bath it is dipped into a container of concentrated color (dye) for several
minutes. After dying, the part is immersed in clean, boiling water for several minutes to close
the pores and seal the dye by hydrating the crystalline layer and swelling the oxide.

Aluminum alloys

When the electrolytic reduction of alumina (Al2O3) (produced from bauxite) was developed
by Charles Hall in Ohio and Paul Heroult in France in 1886, the first “aluminum internal-
combustionengine-powered vehicles” appeared, and aluminum started to play an important
role in the automotive industry. Since then, alloys of aluminum have been developed,
improving its properties and making it extremely popular in different industries. These alloys
are light weight, strong, electrically and thermally conductive and have good corrosion
resistance. Aluminum alloys can be divided into two major categories: casting and wrought.
Cast is aluminum produced in a foundry. Aluminum ingots are melted in furnaces and the
molten aluminum is poured into molds. Wrought is the aluminum formed of sheet, strip or
bar stock that is “hand-worked”. The aluminum is heated in a forge and hammered to shape.
For wrought alloys a four digit system is used to produce a list of wrought composition
families as follows

- 1xxxControlled unalloyed (pure) composition. Used primarily in the electrical and chemical
industries.

- 2xxxAlloys in which copper is the principal alloying element, though other elements,
notably magnesium, may be specified. They are widely used in aircraft.

- 3xxxAlloys in which manganese is the principal alloying element. Used as a general

purpose alloy for architectural applications and various products.

- 4xxxAlloys in which silicon is the principal alloying element. Used in welding rods and
brazing sheet.

- 5xxxAlloys in which magnesium is the principal alloying element. Used in boat hulls and
other products exposed to marine environments.

- 6xxxAlloys in which magnesium and silicon are principal alloying elements. Commonly
used for architectural extrusions.
- 7xxxAlloys in which zinc is the principal alloying element, but other elements such as
copper, magnesium, chromium and zirconium may be specified. Used in aircraft structural
components and other high-strength applications.

- 8xxx Alloys including tin and some lithium compositions, characterizing miscellaneous
compositions.

Casting compositions are described by a three-digit system followed by a decimal value. The
term “heat treatable” for the aluminium alloys, both wrought and cast, is used for specific
operations employed to increase strength and hardness by precipitation hardening. Thus the
term heat treatable distinguishes these alloys from those alloys in which no significant
strength improvement can be achieved by heating and cooling.

Machine Specification

TELSONIC ULTRASOINC MACHINE (used for USMW)

MAKE-TELESONIC

MODEL-M4000

POWER-3000W

FREQUENCY-20KHZ

NOMINAL PRESSURE-6 bar

Power System-Amplitude Regulated

INSTRON 1195 MACHINE

Machine parameters for test

Sample rate (pts/sec) - 4.552

Crosshead Speed (mm/min) -10.000

Full Scale Load (KN) - 20.000

Gauge Length- 57 mm

TESTING PROCEDURE

The ultrasonic welding is carried out varying amplitude, weld pressure, weld time, and weld
pressure with TELSONIC ULTRASOINC MACHINE. Amplitude was varied 80, 90,100
percentage of maximum amplitude of TELSONIC ULTRASOINC MACHINE, weld
pressure was varied as 1.2, 1.4, 1.6 bar.

Similarly weld time was varied as 0.2, 0.3, 0.4 sec To decrease the no of test cycles and to
simpler the analysis the Taguchi orthogonal array method was used.
Tensile strength measurement was carried out with INSTRON 1195 machine and failure load
is noted for each welded specimens.

RESULTS, ANALYSIS AND DISCUSSION

RESULT

Experiments were designed by the Taguchi method using an orthogonal array that was
composed of three columns and 9 rows. This design was selected based on three welding
parameters with three levels each. The selected welding parameters for this welding were:
amplitude (% of max amplitude), weld pressure (bar), weld time (sec).
From the above table we can see for sample no 3 maximum failure load is observed that is
1.424 KN. With sample no 3, the optimum parameters for welding were 80 (% of max
amplitude), 1.6 bar weld pressure and 0.4 sec weld time. To confirm the optimum parameter
Main Effects Plots for Means were drawn.

Main Effects Plots for Means

From the above 3 Main effects plots for means graph, it was found that at 80 (% of max
amplitude), 1.6 bar weld pressure and 0.3 sec weld time there was maximum failure load, so
this combination of parameters affects most to the failure load hence tensile strength. So for
conformation test, ultrasonic welding was carried out with the above parameters (80% of
max amplitude, 1.6 bar weld pressure, 0.3 sec weld time. Failure load was 1.4371 KN with
the above parameters and that was more than 1.424 KN from Table 4.1. So the parameters
(80% of max amplitude, 1.6 bar weld pressure, 0.3 sec weld time) are optimum for maximum
failure load, hence higher tensile strength.

CONCLUSION

This study is focused on joining of the metal sheets (aluminium & aluminium sheet) using
ultrasonic welding technique. The variables are weld time, weld pressure, amplitude.

Main results obtained from the above study are-

 With increase in amplitude the failure load is decreasing or we can say that the weld
strength or tensile strength is decreasing.

 At moderate weld pressure, failure load or tensile stress is minimum.

 At low or moderate weld time failure load is maximum hence maximum weld strength &
tensile strength

REFRENCES

1. Sancaktar, E. (1999). Polymer adhesion by ultrasonic welding. Journal of adhesion

science and technology, 13(2), 179-201.
2. Macwan, A., & Chen, D. L. (2016). Ultrasonic spot welding of a rare-earth
containing ZEK100 magnesium alloy: effect of welding energy. Metallurgical and
Materials Transactions A, 47(4), 1686-1697.
3. Zhi, Q., Ma, J. M., Tan, X. R., Liu, Z. X., Tian, Z. G., & Wang, P. C. (2021). Single-
sided ultrasonic welding of carbon fiber/Nylon 66 composite. Welding in the
World, 65(10), 2047-2058.
4. Xiu, L., Liu, Z., Lv, G., Ma, J., Jin, F., Dai, H., & Qiao, Y. (2018). Remove welding
residual stress for CFETR vacuum vessel by trailing ultrasonic impact
treatment. Journal of Fusion Energy, 37(4), 193-199.
5. Ni, Z. L., & Ye, F. X. (2016). Dissimilar joining of aluminum to copper using
ultrasonic welding. Materials and Manufacturing Processes, 31(16), 2091-2100.
6. Wagner, G., Balle, F., & Eifler, D. (2012). Ultrasonic welding of hybrid
joints. Jom, 64(3), 401-406.
7. Tondi, G., Andrews, S., Pizzi, A., & Leban, J. M. (2007). Comparative potential of
alternative wood welding systems, ultrasonic and microfriction stir welding. Journal
of Adhesion Science and Technology, 21(16), 1633-1643.
8. Ultrasonic welding of AZ31B magnesium alloy Jian Chen, Yong-Chae Lim, Hui
Huang, Zhili Feng, and Xin Sun
9. Ultrasonic Welding of Polymer–Metal Hybrid Joints Anwer Al-Obaidi and Candice
Majewski

10. Fabrication of polymer electronic boards by ultrasonic embossing and welding

Liangyu Cui · Christof Gerhardy · Werner K. Schomburg · Yanling Tian · Dawei
Zhang

11. Fgh

12. Ultrasonic-assisted laser welding on AISI 321 stainless steel S. Yu. Tarasov1 & A. V.
Vorontsov1 & S. V. Fortuna1 & V. E. Rubtsov1 & V. A. Krasnoveikin1 & E. A.
Kolubaev1

13. Rudolf, R.; Mitschang, P.; Neitzel, M.; Rueckert, C. Welding of High‐Performance
Thermoplastic Composites. Polym. Polym. Compos. 1999, 7, 309–315.

14. Reincke, T.; Hartwig, S.; Dilger, K. Improvement of the adhesion of continuously
manufactured multi‐ material joints by application of thermoplastic adhesive film. Int.
J. Adhes. Adhes. 2019, 93, 102321, doi:10.1016/j.ijadhadh.2019.01.015

15. Reincke, T.; Hartwig, S.; Dilger, K. Improvement of the adhesion of continuously
manufactured multi‐ material joints by application of thermoplastic adhesive film. Int.
J. Adhes. Adhes. 2019, 93, 102321, doi:10.1016/j.ijadhadh.2019.01.015.

16. Fukumoto S, Lum I, Biro E, Boomer DR, Zhou Y. Effects of electrode degradation
on electrode life in resistance spot welding of aluminum alloy 5182. Weld J
2003;82:307S–12S.

17. Jahn R, Cooper R, Wilkosz D. The effect of anvil geometry and welding energy on
microstructures in ultrasonic spot welds of AA6111-T4. Metall Mater Trans A
2007;38:570–83. doi: 10.1007/s11661-006-9087-0.
18. Wagner, G.; Balle, F.; Eifler, D. Ultrasonic Welding of Aluminum Alloys to Fiber
Reinforced Polymers. Adv. Eng. Mater. 2013, 15, 792–803,
doi:10.1002/adem.201300043

19. Palardy, G.; Villegas, I. Smart ultrasonic welding of thermoplastic composites. In

Proceedings of the American Society for Composites‐31st Technical Conference
(ASC), Williamsburg, VA, USA, 19–23 September 2016.

20. Yeh, H.J. Ultrasonic welding of medical plastics. In Joining and Assembly of
Medical Materials and Devices; Zhou, Y., Breyen, M.D., Eds.; Woodhead
Publishing: Oxford, UK, 2013; pp. 296–323, doi:10.1533/9780857096425.3.296.

21. Troughton, M.J. Chapter 11—Induction Welding. In Handbook of Plastics Joining,

2nd ed., William Andrew Publishing: Boston, MA, USA, 2009; pp. 113–120,
doi:10.1016/B978‐0‐8155‐1581‐4.50013‐5.

22. Bolt, S. Ultrasonic Plastic Welding of Carbon Fiber Reinforced Polyamide 6 to

Aluminium and Steel. Delft University of Technology, 2014

23. Wagner, G.; Balle, F.; Eifler, D. Ultrasonic Welding of Hybrid Joints. JOM 2012, 64,
401–406, doi:10.1007/s11837‐012‐0269‐5.

24. Gutnik, V.G.; Gorbach, N.V.; Dashkov, A.V. Some Characteristics of Ultrasonic
Welding of Polymers. FIBER Chem. 2002, 34, 426–432,
doi:10.1023/a:1022912325343.

25. Ganesh, M.; Praba Rajathi, R. Experimental study on ultrasonic welding of aluminum
sheet to copper sheet. Int. J. Res. Eng. Technol. 2013, 2, 161–166.

26. Beyer, W., The bonding process in the ultrasonic welding of metals, Schweisstechnik,
Jan. 1969, pp. 16-20
27. Gutensohn, M., Wagner, G., Eifler, D., Reduction of the Adherence of Aluminum On
Ultrasonic Welding Tools, University of Kaiserslautern, 2004, pp. 78 -90

28. Wodara, J., Sporkenbach, D., “Choice of suitable measurement parameters for the
control of ultrasonic welding processes”, Wissenschaftliche Zeitschrift der
Technischen Hochschule Otto von Guericke Magdeburg, 1985, v.29, n. 8, pp. 77-88

29. EXPERIMENTAL WORK- This has been taken from a thesis which uses the
reference of research paper [25-28] to perform a experiment which is to focused on
joining of the metal sheets (aluminium & aluminium sheet) using ultrasonic welding
technique. The variables are weld time, weld pressure, amplitude.