ULTRASONIC WELDING

Electrical

Solid
State
Welding

Chemical
Friction
Mechanical

Pressure

Ultrosonic
Weld

Definition of 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.

Ultrasonic Welding Process

Clamping
force

Process
Description:
Components of
Sonotrode
ultrasonic welding
tip
system include: Vibration
Transducer
Sonotrode
Anvil

Mass

wedge Transducer

Weldment
Anvil
Force

Ultrasonic Welding Mechanism

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
10-75 KHz
deformation which
promotes
welding.

Clamping
force
Mass

wedge Transducer
Sonotrode
tip
workpiece
Anvil
Force

Process Variations
Spot Welding
Ring Welding
Line Welding - Linear Sonotrode
Continuous Seam Welding - Roller Sonotrode
Microminiature Welding

Typical 1500 ultrasonic

spot-type welding machine
Courtesy AWS handbook

AWS Welding Handbook

100 W
Lateral Drive
Ultrasonic
Welder

AWS Welding Handbook

Typical Ring Welding Applications

Tip in Shape of Weld

AWS Welding Handbook

Attachment for Continuous Ring Welding

AWS Welding Handbook

Tip

Traversing Head for Continuous Seam Welding

AWS Welding Handbook

Welding Variables

Ultrasonic Welding Variables

Ultrasonic power
Clamping force
Welding time
Frequency
Linear Vibration Amplitude

Power Generation

Ultrasonic Welding Power

Generation

Frequency
converter

Electrical
energy

Transducer

Electrical power of 60
Hz is supplied to the
frequency converter.
The frequency
converter converts the
required 60 Hz signal
to the welding
frequency (from 10 to
75 kHz).

Vibratory
transducer

AWS Welding Handbook

Power Generation

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
H = Vickers hardness number
T = thickness of the sheet

Electrical
energy

Frequency
Converter

Vibratory
transducer

Power Requirements

E K(HT )

3/2

Where:
E = electrical energy, W*s (J)
k = a constant for a given welding system
H = Vickers hardness number of the sheet
T = thickness of the sheet in contact with the sonotrode
tip, in. (mm)
The constant K is a complex function that appears to involve primarily
the electromechanical conversion efficiency of the transducer, the
impedance match into the weld, and other characteristics of the welding
system. Different types of transducer systems have substantially different
K values.

Source AWS handbook

AWS Welding Handbook

AWS Welding Handbook

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 Interfacial

Interaction
Localized temperature rises resulting from
interfacial slip and plastic deformation.
Temperature is also influenced by power,
clamping force, and thermal properties of the
material.
Localized Plastic Deformation
Metallurgical phenomena such as recrystallizing,
phase transformation, etc..... can occur.

Ultrasonic Welding Materials Combinations

Source AWS handbook

Extreme Interpenetration
Nickel Foil (top) to Gold-Plated Kovar Foil

Local Plastic Flow

Dark Regions are Trapped Oxide
Nickel Foil (top) to Molybdenum Sheet

Very Little Penetration, Thin

Bond Line, Fiber Flow
Molybdenum Sheet to Itself

AWS Welding Handbook

Comparison With Resistance Spot Weld

AWS Welding Handbook

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

Limitations of Ultrasonic
Welding
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.

Other Process Variations

Ultrasonic Welding of Non-metallic
Ultrasonic Plastic Welding

Welds Can Be Made to Non-Metallic

Substrate Materials Coated with Thin
Layers of Metal Films
Material Welded
Metal Film
Non-Metallic

AWS Welding Handbook

Ultrasonic Welding of Plastics

Advantages
Fast
Can spot or seam weld

Limitations
Equipment complex,
many variables
Only use on small parts
Cannot weld all plastics

0.1.1.2.5.T25.95.12

Applications of Ultrasonic
Welding
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

AWS Welding Handbook

Note weld progression (no weld in center)

AWS Welding Handbook

Starter motor armature with wires

joined in commutator slots by
ultrasonic welding
Ultrasonically welded Helicopter
access door.
Courtesy AWS handbook

Field coil assembled by ultrasonic welding

Courtesy AWS handbook

AWS Welding Handbook

Wire Bundle Placed in Jaws

Ultrasonic
Tying Tool
Metal Tape Fed
Around bundle of
Wires and welded
once, then cut and
welded again.

Ultrasonic
Horn
Bundled Wires

Welds

First Weld Made

Cut and Second Weld Made

Ultrasonic Stitch (Clad) Welding

Sonatrode

Anvil

Louks, et al Ultrasonic Bonding Method US Patenet 6,099,670 Aug. 8, 2000

Ultrasonic Welding of Eraser Holder on Plastic Pencil

Coinon, A, Trajber, Z, Pencil Having and Eraser-Holding

Ferrule Secured by Ultrasonic Welding US Patent 5,774,931
July 7, 1998

Explosive Gas Generator For Auto Air Bag

(Plastic Ultrasonic Weld)
Gas Generating
Explosive Powder
Primer

Plastic Cap
Welded to
Plastic Base
Ultrasonic Weld

Avory, et al Electrical Initiator US Patent 5,763,814 June 9, 1998.