A

Seminar Presentation
on

“ULTRASONIC WELDING”
Presented By-
VAKA PAVANKUMAR -

18BQ5A0322
Introduction:
• In 1938, Lludwig Bergman and some colleagues were
experimenting with ultrasonic waves and their effects on
metal.

• He found that many metals could be combined by using

ultrasonic welding that could not be joined by any other
method.

• It was also found that any metal could be strengthened by

subjecting the metal in its molten state to ultrasonic
vibrations

Referred from google:

 Abstract:
The ultrasonic effect upon the molten metal generates a
smaller grain size, giving the metal more strength.
Ultrasonic welding combines pressure and high frequency
vibration motions to form a solid state bond.
The range ultrasonic frequency used in this welding is from
20kHz to 60kHz. This cool, strong weld capable of joining
such combination as aluminium to steel, aluminium to
tungsten, aluminium to molybdenum and nickel to brass.
Ultrasonic welding has also made it possible to join metals
with vastly different melting temperatures, making strong
rigid joints. Thus many applications previously considered
unweldable can now revaluated
• Principle Of Ultrasonic Welding:
• Ultrasonic welding is a solid state welding
process
• In ultrasonic welding, frictional heat produced
by the ultrasonic waves and force is used for
the joining process. Ultrasonic waves (15-60
kHz) are transferred to the materials under
pressure with a sonometer. Welding times are
lower than 3s.The welding can proceed with or
without the application of external heat.
• This process does not involve the process of
Electrode , Filler Material , Generation of Arc
Principle of Ultrasonic
Welding

Presented
• Literature Survey:

Research Papers Referred:

• 1.Nonlinear Dynamic Analysis of Ultrasonic
Metal Welding Using a Harmonic Balance
Method(2018)
• 2. Technology of thermal welding with
ultrasonic weld joint treatment (2017)

Referred from google:

• 1.Nonlinear Dynamic Analysis of Ultrasonic Metal
Welding Using a Harmonic Balance Method(2018)

• Ultrasonic welding is a widely used industrial technique

whereby high-frequency ultrasonic vibrations are locally
applied to two or more workpieces being held together under
pressure to create first heat and ultimately a solid-state weld.
In the welding process, stick, slip and separation occur at the
interfaces between adjacent workpieces.
• Remark:In this study, a new methodology is proposed to
predict the friction forces by introducing a nonlinear contact
model and simulate the coupled thermal-mechanical
interaction. Mixed programming of MATLAB and ANYSYS is
developed with a harmonic balance method
• Referred from google:
• 2. Technology of thermal welding with ultrasonic
weld joint treatment (2017)
• The paper describes an innovative technology of thermal
welding with ultrasonic weld joint treatment as applied to
aluminum sliding formworks used in NPP construction.
Ultrasonic treatment in the process of welding greatly
increases the strength of formwork weld joints by reducing
their residual stresses, grain size and degassing.
• Remark:
• The paper presents the results of theoretical and
experimental studies of ultrasonic effects on the welded joints
and heat-affected zone.
• Referred from google:
 Advantages of Ultrasonic
Welding :
• High-strength welds.
• Easily automated.
• Fast (no cure or dry time and welds in less
than a second)
• No consumables (fasteners or adhesives)
• Provides tamper-proof hermetic seals.
• Clean and precise.
• Can vibrate contaminates out of
packaging seals.
Disadvantages of Ultrasonic
Welding :
• It cannot be used to produce large joints
(greater than 250 x 300 mm).
• It requires specially designed joints, so it
can make tip contact during
the welding process.
• High tooling cost for the fixtures.
• The ultrasonic welding process is
restricted to the lap joints.
Application of Ultrasonic
Welding :
• Manufacturing of toys
• Joining of electrical and electronic components
• Welding aluminium wire sheet
• Packing , medical industries ,computers
• Aerospace and automotive industries to produce
door panels, steering wheels, and other engine
components

• Referred from google: