Ultrasonic Welding

Abstract

Ultrasonic welding is a new and effective method for joining dissimilar metals, thin foils and fine wires, and this process is now being applied in the fields of electronics, packing, etc. Its practical uses for joing structural members have never developed, as there eixst many difficulties and uncertainties in the bonding of large and thick components. We started to investigate this new technique with the intention to develop its practical applications for joining large structural members likely to be used in various industrial fields. In this report, we introduce the construction and performance of a 4 KW ultrasonic spot type welding machine, and describe the experimental results obtained in joining 52 S-O aluminum alloy sheets 1.6 mm to 2.4 mm. The effects of various fundamental factors power input, tip amplitude, time, clamping load, tip radius, surface roughness, sheet thickness etc. have been investigated, and the recommendable welding conditions established for every sheet gage, in which the maximum weld strengths are obtained. These ultrasonic welds demonstrate that they have high shear strengths which are equal to about two times the strengths in MIL specifications for resistance welds, and also that their fatigue strengths are superior to those of resistance welds. © 1963, JAPAN WELDING SOCIETY. All rights reserved.