What is Ultrasonic Welding and the equipments required for Ultrasonic welding

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In this method of solid state welding, the mechanical vibration is used to force the material to join in each other. This process is mostly used for plastic welding. The mechanical pressure is used to keep the work piece together. It has the ability to join the dissimilar metals. In the process, a high strength weld joint with a good surface quality of weld can be achieved.

In the process, the vice or anvil can be used to hold the material with rigidity. A press machine would be used to apply the required pressure to hold the material together. In the process the mechanical vibration are used as energy source of energy to generate the energy which provide joint in the material. For this purposes the ultrasonic unit is installed. This ultrasonic equipment is consist of a generator to supply the electrical energy with appropriate frequency. The energy is then applied to the specimen by a vibrating tool called sonotrode or horn.

In the process filler rod or any other extra material is not required. It is an efficient and economical process with high rate of production.

 




PROCESS:-

  1. In the process of ultrasonic welding, the tool called ‘sonotrode’ is connected with one part and other part would be clamped. 
  2. The part connected with the tool is kept above to the part fixed in the clamp.
  3. Then the sonotrode or horn will place one part to the other and pressure will be applied.
  4. The pressure will be maintained till the welding is completed.
  5.  During the pressure the tool will vibrate with a certain frequency. The vibration will cause the melting of the material.
  6. After the vibration and melting of material the pressure will be maintained for few more time so that the joint settles appropriately and we get a good quality welding joint.
  7. Then the tool will leave the specimen and goes to its initial position.
  8. Then the part is removed from the clamp and final finishing and cleaning is done.

ADVANTAGES:-

  1. The process is able to produce the welding with high rate of production.
  2. The strength of joint is good and bonding of material is strong.
  3. Process is simple, easy to operate and clean.
  4. The solidification time is less due to applied pressure during solidification.
  5. Large varieties of material can be joined.
  6. Automation can be implemented easily.
  7. High repeatability can b achieved. 

DISADVANTAGES:-

  1. Care should be taken at the time of design of components and tooling.
  2. Design should be done according to the ultrasonic welding setup. it can increase cost. 
  3. the process is noisy.
  4. safety precaution is necessary with good quality safety aids.


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