Ultrasonic welding PPT

CONTENTS

üWhat is advanced welding process?

üWhat is Ultrasonic Welding?

üComponents

üProcess

üApplications

What is advanced welding process?

—Non traditional welding processes.

— Automation can be obtained.

— Some process are done without the use of electrode.

What is Ultrasonic Welding?

üUltrasonic welding is an industrial technique whereby two pieces of plastic or metal are joined together seamlessly through high-frequency acoustic vibrations.

üOne component to be welded is placed upon a fixed anvil, with the second component being placed on top. 

Process:

When bonding material through ultrasonic welding, the energy required comes in the form of mechanical vibrations.

—The welding tool (sonotrode) couples to the part to be welded and moves it in longitudinal direction. 

—Sonotrode Tip is usually made of High Speed Tool Steels for welding,

ü Soft Materials

ü Aluminum

ü Copper

ü Iron

ü Low Carbon Steel

üThe part to be welded on remains static. Now the parts to be bonded are simultaneously pressed together.

üThe simultaneous action of static and dynamic forces causes fusion of the parts without having to use additional material.

—The acoustic energy is converted into heat energy by friction, and the parts are welded together in less than a second.

—Thus, saves on manufacturing costs and creates  unnoticeable seams in products where appearance is important.

Merits:

 ØNo heat is applied and no melting occurs.

ØPermits welding of thin to thick sections.

ØWelding can be made through some surface coatings.

ØPressures used are lower, welding times are shorter, and the thickness of deformed regions are thinner than for cold welding.

Demerits :

üThe thickness of the component adjacent to the sonotrode tip must not exceed relatively thin gages because of power limitations of the equipment.

üProcess is limited to lap joints.

üButt welds can not be made because there is no means of supporting the work pieces and applying clamping force.

Applications:

üAssembling of electronic components such as diodes and semiconductors.

üUsed in the assembly of large plastic components and electrical components such as instrument panels, door panels, lamps, air ducts, steering wheels.

üMany everyday items are either created or packaged using ultrasonic welding techniques.