Papers by Keyword: Ultrasonic Welding

Abstract: The demand for lightweight, multifunctional, and durable hybrid structures is rapidly increasing in aerospace, biomedical, and advanced engineering sectors. Ultrasonic welding (USW) offers a promising route to assemble thermoplastic polymers with dissimilar materials such as stainless steel, aluminium, and ceramics, without adhesives or additional fasteners. This study investigates the ultrasonic joining of high-performance thermoplastics, including carbon fibre-reinforced polyetheretherketone (PEEK), and polyetherimide (PEI) as energy director (ED), with aluminium alloys. Improvement of manufacturing efficiency and weld attributes such as welded area, strength, and failure mechanisms are essential for industrial adoption. In this work, particular attention was given to the effect of metal surface preparation and ED film on weld quality. Weld attributes were analysed in terms of joint area continuity, interfacial morphology, tensile shear strength, and observed failure modes. Whereas not all parameter sets led to successful joining, the findings provide insight into the role of surface finish and ED in determining weldability. These results contribute to the ongoing development of reliable welding for hybrid joining between thermoplastics and metals, highlighting opportunities for thermal process innovation beyond conventional approaches.

Abstract: This study's goal is to monitor and evaluate, without undertaking experimental trials, how different materials used in 3D printing behave when exposed to ultrasonic welding. Ultrasonic welding is a solid-state technique that eliminates the need for adhesives, solders, or mechanical fasteners by applying high-frequency ultrasonic acoustic vibrations to workpieces that are kept under pressure. When combining disparate materials, such metals and plastics, this method works especially well. This paper focuses on the theoretical analysis of ultrasonic welding for ABS and ONYX 3D-printed materials. This study intends to shed light on the compatibility, weld quality, and structural integrity of these materials under ultrasonic welding settings by examining current data and research. The results will advance knowledge about the suitability of ultrasonic welding for 3D-printed materials in manufacturing and industrial contexts.

Abstract: This research focuses on optimizing ultrasonic welding technology for joining 3D printed metal composites. The study investigates the influence of various welding parameters, including ultrasonic frequency, amplitude, pressure and welding time, on the quality and strength of the welded joint. The research aims to identify the optimal welding conditions that ensure robust and reliable bonding of these complex materials, given their unique microstructural and mechanical properties. The findings will contribute to the development of efficient and reliable joining techniques for 3D printed metal composites, expanding their applicability in various engineering applications.

Abstract: In recent years, the field of ultrasound has seen remarkable advancements, mainly due to its close ties with the mechanical industry, recognized as the most dynamic industry of the last forty years. The application of ultrasound in the mechanical field has been guided by the advantages it offers, while the most significant advancements are related to the relatively low surface temperature compared to eroded surfaces, the evident localized accumulation, and the possibility of achieving dimensional improvements ranging from sub-millimeter values to centimeter values.

Abstract: Ultrasonic welding is a process that has been in continuous development since it was first introduced in the 1940s. The process is widely used to join or reform plastic or metal materials using mechanical vibrations propagated at frequencies ranging from 20.000 Hz to gigahertz levels. These vibrations produce heat that melts the materials to be welded at their contact surface. In addition to the heat produced by the vibrations, a preset pressure is applied from the control panel of the welding machine to ensure perfect contact between the welded parts.[1] The ultrasonic welding process is time-efficient, taking less than 0.2 seconds in some cases, and does not damage the outer surface of the parts. The whole paper is structured in two parts, one theoretical and one practical, these parts are divided into six chapters. The first chapter of the paper explains the propagation process of ultrasound and what it actually is, as well as a brief history of ultrasound. In the second chapter there are generalities about ultrasonic welding and how this process is carried out and a history of ultrasonic welding. The third chapter introduces us to the subject of the paper, namely ultrasonic welding of plastics. Chapter four deals with the materials used to produce seat belts and their evolution over time. In chapter five we present all the equipment used for the case study. Chapter six is the case study and the explanation of all the steps performed to find out some results about ultrasonic welding of seat belt samples. Finally, I presented the conclusions drawn from the whole research process and the results obtained for the ultrasonic welding process of seat belts.

Abstract: The purpose of this paper is to study the strength characteristics of V4 resin components that are welded using ultrasonics. These components are created using the Low Force Stereolithography (LFS) technology, which reduces the printing forces for achieving the best possible finish. Welding components are 3D printed with a Form 3+ 3D printer, known for its high printing precision, employing a powerful laser and a spatial filter. Key characteristics of the ultrasonically welded components can be extracted, analysed, and summarized to provide guidance on the optimal resin selection.

Abstract: Industrial requirements to establish metallic joints between dissimilar metals in the electric area. The ultrasonic welding process is an optimal process to joint thin sheets or foils. The goal of the research was to optimize the ultrasonic welding parameters to join thin nickel-coated copper sheets and aluminium sheets. It used a 0.5 mm thick high-purity copper (Cu-OF-R200) sheet coated with a 10 μm pure nickel layer and a 0.5 mm thick aluminium (1050A H24) sheet. The ultrasonic welding is made by a Branson Ultraweld L20 ultrasonic welder equipment. The mechanical properties and exacting geometrical tolerance of the joint were required. The welding parameter optimization is made empirically, with several welding tests. The optimal welding parameters were confirmed by non-destructive and destructive tests of the joints. The non-destructive tests were the visual inspection and geometrical measurements of the joint sizes. The destructive tests were tensile tests and macroscopic and microscopic tests. The completed test results confirmed the process applicability and the quality of the joint.

Abstract: Ultrasonic welding is an environmentally friendly, nontoxic welding process preferred by top industrial manufacturers and in accord with the European circular economy regulation. Ultrasonic welding is an environmentally friendly, nontoxic welding process preferred by top industrial manufacturers and in accord with the European circular economy regulation. This scientific article analyses the ultrasonic welding behaviour of composites fabricated by additive manufacture technology using reinforcements, such as: glass fibre, Kevlar, Cu wire, etc. These materials are organized in a „sandwich” structure with different reinforcements and welded by ultrasound. Results were interpreted and compared with base material after performing NDT and destructive tests, namely: visual analysis, microscopic and macroscopic investigations: tensile tests, hardness tests, bending tests.

Abstract: This paper aims to highlight the advantages of using the ultrasonic welding process to join Cu alloy connector with Cu conductor wire, materials that are widely used in the automotive industry. Ultrasonic welding is a “cold”, ecological joining process, which does not produce noxious substances and is of great interest for subassembly manufacturers operating in today’s circular economy. In order to optimize the functional parameters for the connector and conductor wire in question, we use a sonotrode (active tool) made of tool steel, at the operating frequency of 20kHz, designed and executed in INCD ISIM Timișoara; experiments were undertaken to define the welding technology parameters for the materials subjected to the experimental investigation. The results were interpreted after the execution of NDT and destructive tests, namely: visual analysis, microscopic and macroscopic investigations; hardness tests.

Abstract: Ultrasonic-assisted soldering welding is widely applied for joining difficult materials. The cavitation phenomenon in liquid always occurs during the ultrasonic excitation. Base metals are striked by ultrasonic cavitation, creating erosion on the surface. The soft solder materials are penetrated on the rough surface, generated inter-metallic compounds. This work expresses the design of ultrasonic soldering machine using 20 kHz source and steel sonotrode. The curvature of reflecting plates with specific radius and their location are also condidered. The major technological parameters of ultrasonic soldering welding such as ultrasonic exciting time, power and curvature radii of reflecting plate are discussed. Tin soldering material is utilized for joining copper wires and plates are investigated. SEM images on the surface of tin soldering on cooper plates and tensile strength are investigated.