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Joining Technologies
Published in Raghu Echempati, Primer on Automotive Lightweighting Technologies, 2021
Ultrasonic welding creates a solid-state weld by the local application of high-frequency vibrations as the workpieces are held together under pressure (Figure 6.12). This is a cold welding process since the heat generated by the ultrasonic energy is not essential to the formation of the joint. The welding occurs when the ultrasonic tip that is clamped against the workpieces oscillates in the plane parallel to the weld interface.
Introduction
Published in Susanta Kumar Sahoo, Mantra Prasad Satpathy, Ultrasonic Welding of Metal Sheets, 2020
Susanta Kumar Sahoo, Mantra Prasad Satpathy
The superior performance of ultrasonically welded joints, such as high mechanical strength, high corrosion resistance, better electrical conductivity, and better fatigue properties, enables ultrasonic welding to be used in many sectors, including aerospace, automotive, microelectronics, medical, and consumer goods. Illustrations of the modern-day parts made with ultrasonic spot welding appear throughout this section to show the reliability and productivity of this process.
Solid Materials: Joining Processes
Published in Leo Alting, Geoffrey Boothroyd, Manufacturing Engineering Processes, 2020
Ultrasonic welding is used to weld similar or dissimilar materials, including plastics, in overlap joints. Vibrations parallel or perpendicular to the surface of the weldment are generated by an ultrasonic transducer attached to one of the clamping tools, which supplies the necessary clamping or welding force perpendicular to the surface of the weldment. The oscillatory shear or normal stresses break up and remove the oxide layers or contaminants, so that perfect coalescence can be established through the clamping pressure. Ultrasonic welding is mainly used to join sheets, foils and wires, and so on, and can be of the spot or seam type.
Application of sheet-like energy directors to ultrasonic welding of carbon fibre-reinforced thermoplastics
Published in Advanced Composite Materials, 2021
Shin-Ichi Takeda, Jonathon D. Tanks, Sunao Sugimoto, Yutaka Iwahori
Ultrasonic welding is a technique in which ultrasonic vibration is applied to an adherend to melt and join the material together quickly with a pressing force. Since this welding technique utilizes heat generated at the welding surface from friction and viscous damping, it can be applied to various meltable materials. Many studies [9–14] have already been conducted on the ultrasonic welding technology of thermoplastic resins, and the technology has been applied to the production and processing of many industrial products such as automobile parts and packaging products. As such, this section does not summarise the details of the ultrasonic welding principle, focusing instead on the three requirements [15] for improving the efficiency of ultrasonic welding, and what is necessary for the application of this method to the thermoplastic composites.
Development of an optimal scheme for controlling the ultrasonic welding process of artificial leather
Published in Welding International, 2019
S. S. Volkov, V. M. Nerovny, G. A. Bigus
Ultrasonic welding compares favourably with other AL welding methods in that it allows you to obtain a high-quality welded joint even when a non-thermoplastic base and a thermoplastic coating are in contact. Ultrasonic welding can successfully weld IR through a non-thermoplastic substrate with thermoplastic sheet or film substrates made of a material compatible with the AL coating material, as well as in the presence of an intermediate layer, for example, polyurethane foam (PUF), between the AL or AL layers and the substrate. This is due to the fact that under ultrasonic action on infrared thermoplastic coatings, passing into a viscous-flow state, can penetrate (filter) through the pores of the base. At the moment when the fronts of penetrating materials reach each other, the volumetric development of interaction begins, leading to the formation of a welded joint [5,6].
Analysis of ultrasonic welding process of mild steel and 5052 aluminium alloy
Published in Welding International, 2018
Tomohiro Sasaki, Tatsushi Nagai, Takehiko Watanabe
In recent years in order to reduce vehicle body weight, there has been an increase in the use of structures combining steel and aluminium alloys and there have been many studies of techniques for joining these. Ultrasonic welding, a form of solid-phase welding in which vibrations generated by an ultrasonic horn are applied to weld sheets together, is regarded as a promising technique for directly welding dissimilar metals difficult to join using fusion welding methods [1–4]. With this method, the welding tip is attached to the end of the horn and anvil used for welding and frictional heat is generated at the welding surfaces by the sheets being pressed together via these and moved relative to each other. During welding, there are cases in which slippage occurs between the welding tip and the material to be welded which is in contact with this which affects the properties of the joint [5]. Because of this, it is important to gain an understanding of the behaviour of the welding tip as well as that of the welded material in order to comprehend ultrasonic welding phenomena.