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STUDY OF ULTRASONIC WELDING OF PLASTIC AND

POLYMERIC COMPOSITES

Guided by: Submitted by:-

Prof.PRAVEEN A TOMCY THAMPY
ASSISTANT PROFESSOR S7 ME-B
DEPT.OF ME ADR19MEO84
ROLL NO :- 42
MECHANICAL ENGINEERING
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OBJECTIVE

• Study about ultrasonic welding process in plastic and polymeric composites using
high frequencies ultrasonic acoustic vibrations .

• Study of the bonding between plastic materials and polymeric composite

material
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CONTENTS
• INTRODUCTION
• ULTRASONIC WELDING
• MAJOR COMPONENTS
• CLASSIFICATION OF PLASTIC WELDING
• ULTRASONIC WELDING OF PLASTIC
• FEATURES ON ULTRASONIC PLASTIC WELDING
• ADVANTAGES , DISADVANTAGES AND APPLICATIONS
• POLYMERIC COMPOSITES
• ULTRASONIC WELDING OF POLYMERIC COMPOSITE
• FEATURES ON ULTRASONIC COMPOSITE WELDING
• ADVANTAGES AND DISADVANTAGES
• CONCLUSION
• REFERENCES
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introduction

• Ultrasonic welding is a welding process which weld two material each other by
using high frequency ultrasonic acoustic vibrations .

• Here we are studying about welding of two plastic material joining together and
joining to polymeric composite materials.
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ULTRASONIC WELDING

• Ultrasonic welding is an industrial technique whereby high-frequency ultrasonic

acoustic vibrations are locally applied to work piece being held together under
pressure to create a solid state weld.
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MAJOR COMPONENTS

• ANVIL :-
It hold one of the components still while the other is rubbed against it.
It has replaceable head.
• ULTRASONIC TRANSDUCER :-
This component takes an electrical signal from a power supply that is
providing a 20khz AC signal and converts it to a mechanical motion at the same
frequency .
• BOOSTER:-
It increase the amplitude of the motion , at the cost of its force . This
motion is then passed to the ultrasonic horn .
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Major components
• ULTRASONIC HORN:-
This is the portion of the system that actuall vibrates the work piece .
In addition to providing the interface between the ultrasonic generator and the
work piece ,the horn also further amplifies the amplitude of the motion , again
reducing its force . It has replaceable head .
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CLASSIFICATION OF PLASTIC WELDING

• Welding process are categorized by the heating method that is used.

• Two general categories are:
1 . EXTERNAL HEATING
It rely on convection and conduction to heat the weld surface.
Hot tool , hot gas , extrusion , implant induction , implant resistance welding.
2 . INTERNAL HEATING
It rely on conversion of mechanical energy into heat through surface friction.
Ultrasonic , friction , laser ,RF welding.
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ULTRASONIC WELDING of PLASTIC

• In addition to all of the uses of ultrasonic’s in the

welding of metals , the technology can also be
used to weld plastic parts together.
• One primary difference is that rather than
scrubbing the parts together , as in metal
welding , in plastic welding the parts are vibrated
toward and away from each other. This heats and
softens them.
• The continued motion then tends to mix the
softened surfaces of the plastic together ,
forming both a physical , and if the plastics are
selected correctly , a chemical bond between the
parts.
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The horn The horn The vibrations

applies pressure vibrates vertically create frictional
to the plastic at 20,000 to heat that causes
materials 40,000 times the materials to melt
per second and flow together
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FEATURES Of ultrasonic plastic welding

• One of the best combination of plastics for this kind of welding is ABS and acrylic.
• Polymers such as PE , PP AND PIA are crystalline and tend to absorb vibrations
before the energy from the ultrasonic welder can pass through to the weld site .
• Spot welders is used in ultrasonic welding machine for welding plastic.
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ADVANTAGES
• Fast welding speeds , high welding strength and good sealing performance .
• Suitable replacement for traditional welding processes
• It doesn’t use harmful solvents or glue while also not damaging the product.

DISADVANTAGES
• When the thickness and hardness of the plastics parts are increased , the power
required for welding increases. This increase the manufacturing cost of the
ultrasonic welding machine .
• If the power is too large , the design and manufacturing of the acoustic system
and the process effect will produce a series of problem that are difficult to
solve.

APPLICATIONS
• Ultrasonic welding is not suitable for use with thermos setting plastic.
• Most common uses are in the Automotive , Medical , Textile , Food , Plastics and
Packaging industries.
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Polymeric composites

• A polymeric composite is a multi – phase material in which reinforcing fillers are

integrated with a polymer matrix . Resulting in synergistic mechanical properties
that cannot be achieved from either component alone . The fiber is most often
glass , but sometime kevlar , carbon fiber , or polyethylene .
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Ultrasonic welding of polymeric composite

• It means welding of two different material using high-
frequency ultrasonic acoustic vibrations .
• The vibration is transformed into heat during welding in
two ways : at the start of the welding process , heat is
generated on the border between the two over-lapped
specimens because of the friction between them .
• The amount of heat depends on the surface roughness
and friction coefficient between the specimens .
• Heat is also generated when vibration are dampened
because of the resistance of primary chemical bonds
between atoms , molecules and polymer chains .
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FEATURES ON ULTRASONIC COMPOSITE WELDING

• The most used polymer are :-

Carbon fiber polyetherimide
Carbon fiber polyphenylene sulfide

• Welding time depend upon the power input .

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Advantage and disadvantages

ADVANTAGES
• It is used to join thermoplastic composite structures.
• Provides an excellent bonding strength
• It is more cost efficient as opposed to the conventional adhensive .

DISADVANTAGES
• Surface damaged by sonotrode
• Fibre fracture
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CONCLUSION

• Ultrasonic welding process taken in metal ,platic and polymeric composite are
different from each other.

• If the vibration increase the heat generated between materials will increase and
they also damage the welding material.

• Low cost for welding material.

• It can weld any type of polyeric composite material

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references

• C Domanidis , Y Gao –MECHANICAL MODELING OF ULTRASONIC WELDING .

• G Wagner , F Balle , D Eifler – ULTRASONIC WELDING OF HYBRID JOINTS .
• Somen K Bhudolia , Goram Gohel , Kah Fai Leong and Aminul Islam – ADVANCES
IN ULTRASONIC WELDING WELDING OF THERMOPLASTIC COMPOSITES .
• Zoltan Kiss , TamasTemesi , Eniko Bitay , Tamas Barany , Tibor Czigany –
ULTRASONIC WELDING OF ALL-POYPROPYLENE COMPOSITES .
• D.Grewell , A.Benatar – WELDING OF PLASTICS : FUNDAMENTALS AND NEW
DEVELOPMENTS .
• X Wu , T Liu , W Cai – MICROSTRUCTURE , WELDING MECHANISM , AND FAILURE
OF Al/Cu ULTRASONIC WELDS .
THANK YOU