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.
