scholarly journals Ultrasonic welding of polymer fi lms

2020 ◽  
Vol 1 (11-12) ◽  
pp. 59-62
Author(s):  
S. S. Volkov ◽  
V. M. Nerovny ◽  
G. A. Bigus
Keyword(s):  
Static Pressure ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Seam Thickness ◽  
Welding Seam ◽  
Support Roller ◽  
Self Stabilization

The choice of the method of ultrasonic welding of polymer fi lms is substantiated, its advantages over other welding methods are noted.It is shown that the parameters determining the performance of seam ultrasonic welding process for polymer fi lms are the amplitude of the waveguide oscillations, the welding static pressure and the speed of welding with a fi xed gap on a rotating support roller with self-stabilization of the welding seam thickness.

scholarly journals Static ultrasonic welding of carbon fibre unidirectional thermoplastic materials and the influence of heat generation and heat transfer

2021 ◽  
pp. 002199832097681
Author(s):  
F Köhler ◽  
IF Villegas ◽  
C Dransfeld ◽  
A Herrmann
Keyword(s):  
Cross Sections ◽  
Weld Line ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Thermoplastic Composites ◽  
Squeeze Flow ◽  
Anisotropic Flow ◽  
Lap Shear ◽  
Anisotropic Thermal Conductivity ◽  
Edge Defects

Ultrasonic welding is a promising technology to join fibre-reinforced thermoplastic composites. While current studies are mostly limited to fabric materials the applicability to unidirectional materials, as found in aerospace structures, would offer opportunities for joining primary aircraft structures. However, due to the highly anisotropic flow of a molten unidirectional ply undesired squeeze flow phenomena can occur at the edges of the weld overlap. This paper investigates how the fibre orientation in the plies adjacent to the weld line influences the welding process and the appearance of edge defects. Ultrasonic welding experiments with different layups and energy director configurations were carried out while monitoring temperatures at different locations inside and outside the weld overlap. The joints were characterized by single lap shear tests, analysis of corresponding fracture surfaces and microscopic cross-sections. Results showed that the anisotropic flow and the anisotropic thermal conductivity of the plies adjacent to the weld line have a distinct effect on the appearance and location of edge defects. By using energy directors that cover only part of the weld overlap area a new approach was developed to mitigate edge defects caused by the highly directional properties of the unidirectional plies.

Experimental Investigations on Aluminium Ultrasonic Welding Parameters

2014 ◽  
Vol 657 ◽  
pp. 306-310
Author(s):  
Lăcrămioara Apetrei ◽  
Vasile Rață ◽  
Ruxandra Rață ◽  
Elena Raluca Bulai
Keyword(s):  
Microstructural Analysis ◽  
Base Material ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Experimental Investigations ◽  
Welding Parameters ◽  
Material Structure ◽  
Welding Temperature ◽  
Wide Range ◽  
Made In

Research evolution timely tendencies, in the nonconventional technologies field, are: manufacture conditions optimization and complex equipments design. The increasing of ultrasonic machining use, in various technologies is due to the expanding need of a wide range materials and high quality manufacture standards in many activity fields. This paper present a experimental study made in order to analyze the welded zone material structure and welding quality. The effects of aluminium ultrasonic welding parameters such as relative energy, machining time, amplitude and working force were compared through traction tests values and microstructural analysis. Microhardness tests were, also, made in five different points, two in the base material and three in the welded zone, on each welded aluminium sample. The aluminum welding experiments were made at the National Research and Development Institute for Welding and Material Testing (ISIM) Timişoara. The ultrasonic welding temperature is lower than the aluminium melting temperature, that's so our experiments reveal that the aluminium ultrasonic welding process doesn't determine the appearance of moulding structure. In the joint we have only crystalline grains deformation, phase transformation and aluminium diffusion.

Transient Temperature and Heat Flux Measurement in Ultrasonic Joining of Battery Tabs Using Thin-Film Microsensors

2013 ◽  
Vol 135 (5) ◽  
Author(s):  
Hang Li ◽  
Hongseok Choi ◽  
Chao Ma ◽  
Jingzhou Zhao ◽  
Hongrui Jiang ◽  
...  
Keyword(s):  
Thin Film ◽  
Heat Flux ◽  
Heat Generation ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Transient Temperature ◽  
Monitoring And Control ◽  
Change Rate ◽  
Flux Change ◽  
And Control

Process physics understanding, real time monitoring, and control of various manufacturing processes, such as battery manufacturing, are crucial for product quality assurance. While ultrasonic welding has been used for joining batteries in electric vehicles (EVs), the welding physics, and process attributes, such as the heat generation and heat flow during the joining process, is still not well understood leading to time-consuming trial-and-error based process optimization. This study is to investigate thermal phenomena (i.e., transient temperature and heat flux) by using micro thin-film thermocouples (TFTC) and thin-film thermopile (TFTP) arrays (referred to as microsensors in this paper) at the very vicinity of the ultrasonic welding spot during joining of three-layered battery tabs and Cu buss bars (i.e., battery interconnect) as in General Motors's (GM) Chevy Volt. Microsensors were first fabricated on the buss bars. A series of experiments were then conducted to investigate the dynamic heat generation during the welding process. Experimental results showed that TFTCs enabled the sensing of transient temperatures with much higher spatial and temporal resolutions than conventional thermocouples. It was further found that the TFTPs were more sensitive to the transient heat generation process during welding than TFTCs. More significantly, the heat flux change rate was found to be able to provide better insight for the process. It provided evidence indicating that the ultrasonic welding process involves three distinct stages, i.e., friction heating, plastic work, and diffusion bonding stages. The heat flux change rate thus has significant potential to identify the in-situ welding quality, in the context of welding process monitoring, and control of ultrasonic welding process. The weld samples were examined using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) to study the material interactions at the bonding interface as a function of weld time and have successfully validated the proposed three-stage welding theory.

scholarly journals Monitoring of the ultrasonic welding process

2020 ◽  
Author(s):  
M. Kornely ◽  
J. Rittmann ◽  
M. Kreutzbruck
Keyword(s):  
Welding Process ◽  
Ultrasonic Welding

FEA of SAW penetration of Ramor 500 steel

2020 ◽  
Vol 62 (12) ◽  
pp. 1192-1198
Author(s):  
Ali Kaya Gur ◽  
Semih Taskaya ◽  
Subramaniam Shankar ◽  
Thangamuthu Mohanraj
Keyword(s):  
Three Dimensional ◽  
Welding Process ◽  
Source Model ◽  
Strength Properties ◽  
Steel Plates ◽  
Constant Current ◽  
Welding Seam ◽  
Depth Increase ◽  
Thermal Cooling ◽  
Submerged Arc

Abstract Ramor 500 steel plates are used as a ballistic material due to their greater hardness and strength properties. This steel can be produced with a 2-30 mm thickness sheet which may attain 505-590 HV hardness. In the present work, Ramor 500 steel pairs are joined using a submerged arc welding (SAW) process and taking various parameters into consideration. An austenitic additional wire is used for the welding process which contains Cr, Ni, and Mn. The source model prototype was developed using ANSYS software and considering a time-dependent three dimensional thermal model with source cooling. The highest tensile stress voltage value was determined in the sample applying a constant current of 250 A, 25 V and 30 cm × min-1welding speed. It was observed that the welding seam width increases as welding tension grows and that welding height and depth increase and decrease more or less in tandem. A ANSYS thermal cooling analysis revealed that welding tension grows with heat transfer which increases 15 mm from the main center of the welding area.

An Investigation of Dissimilar Welding Aluminum Alloys to Stainless Steel by the Tungsten Inert Gas (TIG) Welding Process

2017 ◽  
Vol 904 ◽  
pp. 19-23
Author(s):  
Van Nhat Nguyen ◽  
Quoc Manh Nguyen ◽  
Dang Thi Huong Thao ◽  
Shyh Chour Huang
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloy ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Welding Current ◽  
Tig Welding ◽  
Inert Gas ◽  
Dissimilar Welding ◽  
Adjacent Area ◽  
Welding Seam

Welding dissimilar materials has been widely applied in industries. Some of them are considered this as a strategy to develop their future technology products. Aluminum alloy and stainless steel have differences in physical, thermal, mechanical and metallurgic properties. However, selecting a suitable welding process and welding rods can solve this problem. This research aimed to investigate the T-joint welding between A6061 aluminum alloy and SUS304 stainless steel using new welding rods, Aluma-Steel by the Tungsten Inert Gas (TIG) welding process. The mechanical properties, the characteristics of microstructure, and component analysis of the welds have been investigated by the mechanical testing, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). As a result, the fracture occurred at the adjacent area between welding seam and A6061 alloys plate. The thermal cracking appeared at central welding-seam along the base metals if high welding current. A large amount of copper elements found in the welds due to using the new welding rod, Aluma-Steel rod.

Determination of Ultrasonic Welding Optimal Parameters for Thermoplastic Material of Manufacturing Products

2013 ◽  
Vol 64 (1) ◽  
Author(s):  
Rashiqah Rashli ◽  
Elmi Abu Bakar ◽  
Shahrul Kamaruddin
Keyword(s):  
Electronic Device ◽  
Low Cost ◽  
Near Field ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Field Configuration ◽  
Welding Parameters ◽  
Optimal Parameters ◽  
Thermoplastic Material

Ultrasonic welding had been widely used in various manufacturing industries such as aviation, medical, electronic device and many more. It offers a continued safe operation, faster and also low cost as it able to join weld part less than one second and also simple to maintain the tooling devices. Though ultrasonic welding brings a lot of advantages in assembly especially in thermoplastic material of manufacturing product, it also has a dominant problem to be deal with. The problem in ultrasonic welding is poor weld quality due to improper selection of ultrasonic welding parameters especially in near field configuration. Thus, an optimal combination of parameters is crucial in order to produce good quality weld assembly for this configuration. In this paper, ultrasonic welding process, ultrasonic weld joint defects and determination of optimal parameters for thermoplastic material had been discussed thoroughly. 

scholarly journals Contemporary Progresses in Ultrasonic Welding of Aluminum Metal Matrix Composites

2021 ◽  
Vol 8 ◽  
Author(s):  
Senthil Kumaran Selvaraj ◽  
Kathiravan Srinivasan ◽  
Utkarsh Chadha ◽  
Rajat Mishra ◽  
Kurane Arpit ◽  
...  
Keyword(s):  
Metal Matrix Composite ◽  
Metal Matrix Composites ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Matrix Composites ◽  
Aluminum Metal ◽  
Aluminum Metal Matrix Composites ◽  
Aluminium Metal

Graphical AbstractA Brief Review of the Ultrasonic welding process flow and sequence for joining aluminium metal matrix composite.

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