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ultrasonic welding

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Mohamed Abu Elhamayel
Mohamed Abu Elhamayel

this presentation is about ultrasonic welding ,it shows what is ultra sonic welding and how does it work with some applications . I am a student at port said university ,faculty of engineering ,production and mechanical design department .

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Ultrasonic welding Made by : Mohamed hamdy mandoh Mohamed nasr aboelhamayel Nader salama ebrahim Presented to: Dr . Hassan abd elhafez
CONTENTS INTRODUCTION WHY TO USE US WELDING ULTRASONIC WELDING PROCESS ULTRASONIC WELDING MECHANISM PRINCIPLE OF ULTRASONIC MACHINING JOINT FORMS WITH ULTRASONIC MACHINING SPOT WELDING IN AIRCRAFT WINGS ADVANTAGES DIS ADVANTAGES APPLICATION
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.
Solid State Welding Electrical Chemical Mechanical Friction Pressure Ultrosonic Weld Flow chart of solid state welding
MAIN PARTS TRANSDUCER Produces high frequency ultrasonic vibrations. CONVERTOR Converts the electrical signal into a mechanical vibration
BOOSTER Modifies the amplitude of vibrations SONOTRODE Applies the mechanical vibrations to the parts to be welded Anvil MAIN PARTS
Ultrasonic Welding Mechanism A static clamping force is applied perpendicular to the interface between the work pieces. The contacting sonotrode oscillates on the interface. Combined effect of static and oscillating force produces deformation which promotes welding. Anvil Sonotrode tip Clamping force wedge Transducer Force workpiece 10-75 KHz
Principle of Ultrasonic Welding Anvil Mass Sonotrode tip Clamping force wedge Transducer Force WeldmentVibration *In US welding, frictional heat produced by the ultrasonic waves and force is used for joining process. *US waves(15to60 kHz) are transferred to the material under pressure with a sonometer. Welding times are lower than 3 s. *It can proceed with or without the application of external heat.
Ultrasonic Welding 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, W*s (J) H = Vickers hardness number T = thickness of the sheet Electrical energy Frequency Converter Vibratory transducer
Interfacial Interaction Localized Plastic Deformation Localized temperature rises resulting from interfacial slip and plastic deformation. Temperature is also influenced by power, clamping force, and thermal properties of the material. Metallurgical phenomena such as recrystallizing, phase transformation, etc..... can occur.
ultrasonic welding
Why to use US welding? First - Ultrasonic assembly uses ultrasonic vibratory energy which is transmitted through the parts to melt and bond thermoplastic materials And joining thin sheet gauge metals and other lightweight materials Second - This technique is fast, efficient, non-contaminating . Third - In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together.
Types of US welding Spot Welding Line Welding - Linear Sonotrode Continuous Seam Welding - Roller Sonotrode
. Types of Ultrasonic Welding
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
ultrasonic welding
ultrasonic welding
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 Dissimilar metals having vastly different melting points can be joined Pressures used are lower, welding times are shorter, and the thickness of deformed regions are thinner than for cold welding
Limitations of Ultrasonic Welding Competitively not economical Process is limited to lap joints. Butt welds can not be made because there is no means of supporting the work pieces and applying clamping force. Due to fatigue loading the life of equipment is short. This process is limited to small welds of thin, malleable metals Eg: Aluminium, Copper, Nickel
Applications of Ultrasonic Welding Computer and electrical industries delicate circuits, Junctions of wire harnesses , flash drives and computer disks, Semiconductor devices Aerospace and automotive industries instrument panels, door panels, lamps, air ducts, steering wheels, and engine components Medical industry
Applications Manufacturing of toys Joining of electrical and electronic components Welding aluminium wire and sheet Mobiles, sports shoes , laminations, cars. Packing , medical industries, computers. 6/8/2014SUBHASIS.....MIT BBSR 21
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ultrasonic welding

  • 1. Ultrasonic welding Made by : Mohamed hamdy mandoh Mohamed nasr aboelhamayel Nader salama ebrahim Presented to: Dr . Hassan abd elhafez
  • 2. CONTENTS INTRODUCTION WHY TO USE US WELDING ULTRASONIC WELDING PROCESS ULTRASONIC WELDING MECHANISM PRINCIPLE OF ULTRASONIC MACHINING JOINT FORMS WITH ULTRASONIC MACHINING SPOT WELDING IN AIRCRAFT WINGS ADVANTAGES DIS ADVANTAGES APPLICATION
  • 3. 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.
  • 5. MAIN PARTS TRANSDUCER Produces high frequency ultrasonic vibrations. CONVERTOR Converts the electrical signal into a mechanical vibration
  • 6. BOOSTER Modifies the amplitude of vibrations SONOTRODE Applies the mechanical vibrations to the parts to be welded Anvil MAIN PARTS
  • 7. Ultrasonic Welding Mechanism A static clamping force is applied perpendicular to the interface between the work pieces. The contacting sonotrode oscillates on the interface. Combined effect of static and oscillating force produces deformation which promotes welding. Anvil Sonotrode tip Clamping force wedge Transducer Force workpiece 10-75 KHz
  • 8. Principle of Ultrasonic Welding Anvil Mass Sonotrode tip Clamping force wedge Transducer Force WeldmentVibration *In US welding, frictional heat produced by the ultrasonic waves and force is used for joining process. *US waves(15to60 kHz) are transferred to the material under pressure with a sonometer. Welding times are lower than 3 s. *It can proceed with or without the application of external heat.
  • 9. Ultrasonic Welding 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, W*s (J) H = Vickers hardness number T = thickness of the sheet Electrical energy Frequency Converter Vibratory transducer
  • 10. Interfacial Interaction Localized Plastic Deformation Localized temperature rises resulting from interfacial slip and plastic deformation. Temperature is also influenced by power, clamping force, and thermal properties of the material. Metallurgical phenomena such as recrystallizing, phase transformation, etc..... can occur.
  • 12. Why to use US welding? First - Ultrasonic assembly uses ultrasonic vibratory energy which is transmitted through the parts to melt and bond thermoplastic materials And joining thin sheet gauge metals and other lightweight materials Second - This technique is fast, efficient, non-contaminating . Third - In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together.
  • 13. Types of US welding Spot Welding Line Welding - Linear Sonotrode Continuous Seam Welding - Roller Sonotrode
  • 15. 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
  • 18. 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 Dissimilar metals having vastly different melting points can be joined Pressures used are lower, welding times are shorter, and the thickness of deformed regions are thinner than for cold welding
  • 19. Limitations of Ultrasonic Welding Competitively not economical Process is limited to lap joints. Butt welds can not be made because there is no means of supporting the work pieces and applying clamping force. Due to fatigue loading the life of equipment is short. This process is limited to small welds of thin, malleable metals Eg: Aluminium, Copper, Nickel
  • 20. Applications of Ultrasonic Welding Computer and electrical industries delicate circuits, Junctions of wire harnesses , flash drives and computer disks, Semiconductor devices Aerospace and automotive industries instrument panels, door panels, lamps, air ducts, steering wheels, and engine components Medical industry
  • 21. Applications Manufacturing of toys Joining of electrical and electronic components Welding aluminium wire and sheet Mobiles, sports shoes , laminations, cars. Packing , medical industries, computers. 6/8/2014SUBHASIS.....MIT BBSR 21

Editor's Notes

  • #9: Typical components of an ultrasonic welding system are illustrated in the above figure. Linear ultrasonic vibrations are generated in the transducer and transferred to a sonotrode. The anvil holds the components in a fixed position and supports the clamping force.
  • #10: The energy required to make an ultrasonic weld can be related to the hardness of the workpieces and the thickness of the part in contact with the sonotrode tip. Analysis of data covering a wide range of materials and thickness has led to the above empirical relationship. The constant k is a complex function that appears to involve primarily the electro-mechanical conversion efficiency of the transducer, the impedance match into the weld, and other characteristics of the welding system. Different types of transducer systems should have substantially different k values.