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Electrical
Solid
State
Welding
Chemical
Friction
Mechanical
Pressure
Ultrosonic
Weld
Clamping
force
Mass
wedge Transducer
Sonotrode
tip
Vibration
Weldment
Anvil
Force
Mass
wedge Transducer
Sonotrode
tip
workpiece
Anvil
Force
Process Variations
Spot Welding
Ring Welding
Line Welding - Linear Sonotrode
Continuous Seam Welding - Roller Sonotrode
Microminiature Welding
100 W
Lateral Drive
Ultrasonic
Welder
Welding Variables
Ultrasonic power
Clamping force
Welding time
Frequency
Linear Vibration Amplitude
Power Generation
Frequency
converter
Electrical
energy
Transducer
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).
Vibratory
transducer
Power Generation
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 sheet
Electrical
energy
Frequency
Converter
Vibratory
transducer
Power Requirements
E K(HT )
3/2
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.
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.
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