Ultrasonic Welding Related Literature

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A good number of literatures both on FSW and Ultrasonic welding have been reviewed and studied to get a clear comprehension of the techniques and methods employed in the study. Here an attempt has been made to get useful information regarding the field of study.
The basic principle of FSW has already been explained where a spinning tool is plunged into the work piece as shown in Fig.2.1. The spinning tool is made of a specially designed pin along with a shoulder. Due to the spinning operation of the tool on the work piece heat is generated by friction and it causes plastic deformation of the material. Thus material surrounding the pin gets softened due to localized heating. The weld is formed in solid state condition.

Fig.2.1: Schematic …show more content…

The material reaches to a state of 50% of its melting point. When compared with hot isostatic pressure welding or fused deposition process lower pressure is required with Ultrasonic welding while joining thin to thick sections of material. Only nonferrous materials and their alloys are successfully welded using Ultrasonic welding and many other materials are yet to be tested with the feasibility of Ultrasonic welding. A one of the most widely used system for ultrasonic welding is shown in Fig.2.6. Here on the interface portion between the work pieces a static normal force is applied in perpendicular direction and a oscillation is given to the sonotrode in a direction parallel to the interface surface of the materials [10]. The integrated effect of oscillating and static forces promotes deformation which further results into welding.

Fig.2.6: Principle of ultrasonic welding set up for spot welding [10]

Chang and Frisch [11] did their research to evaluate the principle behind the bonding mechanism in Ultrasonic welding. Due to Ultrasonic vibration how the bonded are evolves is shown in Fig.2.7. According to their study there are two different processes via which bonding occur. They are namely interfacial slip and sublayer plastic deformation which results into a localized rise in temperature at the weld. In the weld zones the maximum average interfacial temperature …show more content…

[13] did their research on ultrasonic welding to propose effective ultrasonic welding variables and parameters depending on the work piece size. An ultrasonic welding system for butt welding was developed for joining large and relatively thicker materials. The maximum thickness of the specimen that can be welding using convention lap spot welding is around 2 to 3 mm. An attempt was made in joining 6mm thick Aluminium plates where the driving position of the welding tip was shifted to move along the width of the specimen. Another method for joining medium to relatively large materials a special method of two vibration systems was innovated. An ultrasonic wire bonding system is also found to be effective for joining metal specimens of small

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