1. Ultrasonic Welding
Welding Technology/ 3.4 Ultrasonic Welding

2. Ultrasonic Welding
A solid state welding process in which coalescence is produced at the faying surfaces by the application of high frequency vibratory energy while the work pieces are held together under moderately low static pressure. OR
Ultrasonic welding is a welding technique whereby high-frequency ultrasonic vibrations are locally applied to work pieces being held together under pressure to create a solid state weld
Welding Technology/ 3.4 Ultrasonic Welding

3. Ultrasonic Welding
Welding Technology/ 3.4 Ultrasonic Welding

4. Ultrasonic Welding
A static clamping force is applied perpendicular to the interface between the work pieces.
The contacting sonotrode oscillates parallel to the interface.
Combined effect of static and oscillating force produces deformation which promotes welding.
Welding Technology/ 3.4 Ultrasonic Welding

5. 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
Welding Technology/ 3.4 Ultrasonic Welding

6. Advantages No heat is applied and no melting occurs.
Permits welding of thin to thick sections.
Welding can be made through some surface coatings.
Pressures used are lower, welding times are shorter, and the thickness of deformed regions are thinner than for cold welding.
It is much faster than conventional adhesives or solvents.
Drying time is very quick
Site of weld is very clean and rarely requires any touch-up work
Welding Technology/ 3.4 Ultrasonic Welding

7. Limitations
The thickness of the component adjacent to the sonotrode tip must not exceed relatively thin gages because of power limitations of the equipment.
Process is limited to lap joints.
Butt welds can not be made because there is no means of supporting the workpieces and applying clamping force
This process is limited to small welds of thin, malleable metals
Eg: Aluminium, Copper, Nickel.
Ultrasonic would not be used in welding, pieces of a bicycle or automobile together, due to the power levels required
Welding Technology/ 3.4 Ultrasonic Welding

8. Applications
Assembling of electronic components such as diodes and semiconductors with substrates.
Electrical connections to current carrying devices including motors, field coils, and capacitors.
Encapsulation and packaging.
Plastic parts
Microcircuit connections, sheet metal, foils, ribbons and meshes are often joined using ultrasonic welding
This type of welding is often used to build assemblies that are too small, too complex, or too delicate for more common welding techniques.
Welding Technology/ 3.4 Ultrasonic Welding