Ultrasonic
wel ing
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'Neking
welting
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Ultrasonic
welding
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Principle:
tool (sonotrode) moves longitudinal direction
part to be welded
remains static parts pressed
b
a .plastics
Oscillations are
introduced vertically
b.metals
oscillations
HorizonQlly
1
•
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2
5
1. Sonotrode
2, 3 Parts to be joined
4. Anvil
5. Welding area
frequency
(usually 20 -40 kHz)
I:)
Applications
electronic components
Flat braided wire after fully automatic manufacturing,
both sides e,n d-compressed
Using ultrasonics,
12 wires can be welded onto a terminal
Braided Cu-wire welded to a brass
socket using ultrasonics
Several enameled wires welded
with a silver-coated stranded wire
Copper-to-Aluminum Transition
Joints In AutomotJve
Starter Motor Field Coils
Copper Pede Welded to
Alumnlnum Heat Sinka
Copper-to-aluminum transition joints in distribution transformers
Welding parameters
20 to 40 kHz
0.1 to ---1 second
400-1500N
Materials suitable for ultrasonic welding
copper, aluminum and brass common
lead, zinc and tin cannot be welded due their high lubricity
Nickel-plating, silver-coating, copper-coating
or aluminum-plating often have a positive effect
materials less suitable
apply
suitable surface layer
(for example,
the application of a nickel or galvanized, copper layer on steel).
major area of appllcatlon
bonding of enamel copper wires
such as th,ose used for coils, transformers, etc.
Comparison of bond techniques for splices
Crimping
Crimping
and
soldering
Ultrasonic
welding
3
4
4
2
3
2
3
3
5
Required
energy
3
1
5
2
4,
Process time
1
3
5
1
4
1
2
4
1
4
Soldering
Resistance
welding
Investment
s
Lifetime of
tools
Environmental
factors in
production
area
5 -- very good/ advant.a geous; 4 -- good; 3 -- satisfactory
2 -- sufficient; 1 -- defective/disadvantageous
Table shows advantages and disadvantages of different bonding techniqlJ ~
The tooling w i ll last several hundred thousand cycl •s
Resistance welding tooling will typically need to be changed daily in an aut m ated
environment. This will require down time on the line
Ultrasonic welding is a nonfusion joining method
It uses only about 5% of the energy of resistance weldi ng
and about 20% of the energy required for making a riveted panel. Resistance welding
often requires costly water cooling with its additional recycling and ~rifying costs
Crimping
Crimping
and
soldering
Ultrasonic
welding
3
2
2
4
5
2
3
3
4
Consumables
1
5
1
1
5
Quality
assurance of
the weld
1
3
2
2
5
Consistency of
measuring
values
2
3
3
4
4
Soldering
Resistanc
e welding
Flexibility of
production
(time for toolchange,
required tools)
5
Complexity of
welding
parameters
influencing the
weld
5 - very good/ advantageous; 4 -- good; 3 -- satisfactory
2 - - sufficient; 1 -- defective/disadvantageous
Structure and mode of operation
of an ultrasonic metal welding unit
Rapid development of the ultrasonlc weldlng machine ha• occurred In the laat ten years.
Basic fu"cttons, such as weld energy, collapse, trigger force, and pressure ant now microprocessorcontrolled.
In addition, real time feedback and control of weldlng condlUona la being offered, along with the ablllty to
vary weld force and amplltude during the weld cycles.
equipment consi sts of
*an ultrasonic generator
*the ultrasonic welder with
ultrasonic transducer system
Fig. 8
.
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Ultrasonic generator
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The ultrasonic generator
operates with
AC line voltage
(220/110 volts).
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It generates a sinusoidal
wave of 20 kHz from the
supplied power.
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Equipment with 35 and 40
kHz operating frequency
are also standard.
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IC
ultrasonic generator