Ultrasonic welding is the use of ultrasonic frequency (more than 20,000 Hz) of mechanical vibration energy, connecting the same or dissimilar metals, semiconductors, plastics and metal ceramics and other materials of special welding methods. This is my ultrasonic welding technology paper for everyone, just for reference!
Ultrasonic welding technology paper aResearch and Prospect of Ultrasonic Welding
Abstract: Ultrasonic welding's energy saving, environmental protection, easy to operate and other outstanding advantages, more and more people's attention. Ultrasonic welding has been widely used in many fields. This paper briefly introduces the basic principle of ultrasonic welding. It summarizes the current status of the domestic development of ultrasonic welding, and makes an outlook on the development of ultrasonic welding.
Keywords: ultrasonic welding, research status
0 Introduction
In 1950, Americans invented ultrasonic welding technology, which is widely used in industrial production as a special connection technology. In addition, ultrasonic welding technology is also widely used in electronic industry, electrical appliances manufacturing, equipment of new materials, aerospace and nuclear energy industry, food packaging boxes, sealing technology of advanced parts. The advantages of ultrasonic welding are mainly expressed as: energy saving, environmental protection, easy to operate, this technology plays a great role in promoting the construction of resource-saving, environmentally friendly society in China.
1 ultrasonic welding principle and characteristics [1]
Ultrasonic welding as a special welding method, usually refers to the use of ultrasonic frequency (greater than 16KHZ) of mechanical vibration energy, will be the same or different kinds of metals, semiconductors, plastics, and metal ceramics and so on to connect. When welding metals by ultrasound, on the one hand, there is no need to deliver electric current to the workpiece, on the other hand, no high temperature heat source is introduced into the workpiece, and during the welding process, the elastic vibration energy is transformed into friction work between the workpieces, deformation energy, and a limited temperature rise under the action of static pressure. In the case of the parent material does not melt, to achieve metallurgical bonding between the joints, therefore, ultrasonic welding belongs to the solid state welding.
The working frequency current is further transformed into an oscillating current of ultrasonic frequency (15-16KHZ)d under the action of the ultrasonic generator. Through the magnetostrictive effect, the transducer converts the electromagnetic energy into elastic mechanical vibration energy. The amplifier serves to amplify the amplitude and at the same time couples with the parallel workpiece with the help of the coupling rod and the upper acoustic pole. If the self-oscillating frequencies of the transducer, the amplifier, the coupling rod and the upper acoustic pole coincide with each other, in this case the system will resonate, thus transmitting the elastic vibration energy to the workpiece at static pressure F. The two thin workpieces are bonded together by this conversion between the energies.
2 Current status of domestic research
2.1 Current status of research on ultrasonic metal welding
Cui Yan [2] studied the application of ultrasonic welding in tank aluminum parts welding repair, the weldability of aluminum and aluminum alloy was analyzed in detail, and it is believed that an important factor to ensure the stability of the quality of welded joints is the precision of the resonance frequency. In the ultrasonic welding process, because the mechanical load is variable, the detuning phenomenon will appear randomly, which in turn makes the welded joint quality unstable. According to the characteristics of ultrasonic welding, develop the corresponding welding specifications. A large number of experiments have proved: through the ultrasonic welding of aluminum and aluminum alloy, the dense oxide film on the metal surface can be effectively removed, which in turn ensures the welding quality.
South China University of Technology, Yang Shengwen et al [3] deduced the copper sheet - copper tube solar collector ultrasonic welded joints region of the theoretical regional temperature formula, and the use of artificial thermocouple method to measure the temperature of the welded region, to analyze the measured temperature deviation of the reasons for this, combined with the welded joints of the scanning electron microscope (SEW) pictures for comparative analysis, the study of the formation of the ultrasonic welded joints of copper sheet - copper tube. The formation mechanism of copper sheet-copper tube ultrasonically welded joints was investigated. The results show that: ultrasonic welding is based on the joint area at the tip of the microtooth high temperature, pure metal plastic deformation of the surface to fully affixed on the basis of the two factors of metal bonding and mechanical embedding and the formation of joints in the physical metallurgical process.
Nanjing University of Aeronautics and Astronautics College of Electrical and Mechanical Zhang Qiu Feng [4] studied the 1Cr18Ni9Ti and TC4 dissimilar metal solid state diffusion welding process, on the basis of the existing ultrasonic loading solid state diffusion welding process. Metallographic test analysis results show that the use of ultrasonic loading diffusion welding process, so that the stainless steel and titanium formed a good connection.
Yan Jiuchun and Sun Xiaolei [5] of Harbin Institute of Technology, etc., in the open environment to study a suitable for complex structures, and can make a reliable connection? Ultrasonic vibration-assisted brazing technology? principle, as well as describing the preliminary test results of brazing aluminum matrix composites, aluminum alloys, ceramics/aluminum, and glass/aluminum. The welding results show that by applying appropriate ultrasonic vibration during the brazing process, the oxide film on the surface of the base material can be effectively removed, which further promotes the wetting of the base material with the brazing material. Under low temperature and atmospheric conditions, joints with microstructure and good mechanical properties were obtained.
Zhu Zhengqiang et al. from Nanchang University [6] used electron backscatter diffraction (EBSD) to study the microstructure changes of aluminum alloy AA6061 under ultrasonic welding, to deepen the understanding of ultrasonic metal welding from a microscopic point of view. The grain orientation difference distribution of the original aluminum foil and the welded aluminum foil is obtained through the experiment. Through the analysis of grain orientation, grain structure and grain boundary characteristics to understand the impact of ultrasonic welding on the organization and structure of aluminum alloy.
2.2 The current status of ultrasonic non-metallic welding
Guo Yufeng [7] 12?m polyethylene terephthalate (PET) / 30?m polyethylene (PE) film ultrasonic welding process, found that the welding amplitude of the welding amplitude in the 2-10?m, the welded joints of the thermal bonding strength of the impact is not significant; in the welding amplitude of the welding amplitude of 4-7?m appeared in the welding joints of the thermal bonding strength maximum. The maximum value of thermal bonding strength of welded joints occurred at welding amplitude 4-7?m. The strength of welded joints with the prolongation of the welding time and welding pressure shows the first increase and then reduce the law of change. By analyzing the degree of crystallization of the welded area under different process parameters, the results show that the degree of crystallization of the joint affects the strength of PET/PE film welded joints, the degree of crystallization of the welded area specimens with the increase of the welding time, welding amplitude, welding pressure decreases firstly and then increases, and the strength of the welded joints firstly rises and then decreases.
Zhao Gang [8] and others study the application of ultrasonic welding in automotive sensor packaging. It describes the method of realizing automotive sensor packaging through the selection of materials, welding methods and the design of weld joints and tooling design and manufacturing process design.
Zhao Shibin [9] studied the application of ultrasonic welding in connectors. Briefly introduced the principle of ultrasonic welding, combined with the design of the surface of the design method, design points, as well as in the connector in the specific application and scope of use.
Nie Zhongming [10] of Northwestern Polytechnical University studied the ultrasonic welding of high-resistance CdZnTe semiconductor (CZT for short) contact electrodes and leads. It is believed that: CZT wafers after mechanical polishing surface treatment, prepared by ion sputtering method between the gold electrode and the outer lead has a high ultrasonic welding rate, can obtain the best quality of the welding joint electrode thickness of 180 nm. In addition, to determine the CZT contact electrode preparation process, the wedge pressure becomes the main factor affecting the quality of ultrasonic welding of the CZT contact electrodes and the lead, and the welding power is a secondary factor.
3 Summary
At present, there is a lack of understanding of the welding mechanism of ultrasonic metal, ultrasonic metal welding as a solid-phase welding method, or intermetallic ? bonding? Process, in the welding process, whether no metal melting has to be further studied. There is also the application of ultrasonic waves in material welding, although the welding effect is better, but for the whole system combined by the ultrasonic generator, acoustic system and mechanical system, there are still problems in terms of stability, maneuverability, reliability, etc., so the design of the acoustic system, as well as the connection between the acoustic system and the specimen, etc. are very important. In addition, the study of the effect of ultrasonic vibration on grain and weave from the perspective of micromechanics is also an important direction for future research.
References:
[1] S. Li, Y. S. Li, J. Yun Han. Research on rapid prototyping method based on ultrasonic welding technology[J]. Machine Tools and Hydraulics, 2007, 35(3):4-6.
[2]Cui Yan. Application of ultrasonic welding in the repair of aluminum parts of tanks [J]. Industrial Technology and Economy, 2000, 19(3):114-116.
[3]Yang Shengwen, Wu Zequn, Chen Pingchi. Experimental study on ultrasonic welding of copper sheet-copper tube solar collector panels[J]. Welding, 2005(9):32-35.
[4]Zhang Qufeng. Ultrasonic diffusion welding of titanium and stainless steel[J]. Mechanical Engineering and Automation, 2008(1):125-127.
[5]Yan Jiuchun, Sun Xiaolei. Ultrasonic vibration-assisted brazing technology[J]. Welding, 2009(3):6-12.
[6]Zhu Zhengqiang, Ma Guohong, E. Ghassemieh. Analysis of tissue evolution under ultrasonic welding of aluminum alloy AA6061[A]. Proceedings of the Seventh China Robotic Welding Academic and Technical Exchange Conference [C], 2008: 107-110.
[7]Guo Yufeng. Ultrasonic welding of polyethylene terephthalate/polyethylene films[J]. Aerospace Materials Process, 2010(4):53-55.
[8]ZHAO Gang, CAO Zhi, DONG Shuanghui. Application of ultrasonic welding in automotive sensor packaging[J]. Journal of Shenyang Institute of Aeronautics and Astronautics, 2007(4):25-28.
[9]Zhao Shibin. Application of ultrasonic welding in connectors[J]. Electromechanical Components, 2006(4):36-39.
[10]Nie C.M., Fu L., Ren J., Cha G.Q. Ultrasonic welding of CdZnTe contact electrodes and leads[J]. China Journal of Nonferrous Metals, 2009, 19(5): 919-923.
Ultrasonic welding technology thesis IIUltrasonic welding technology in industrial product design application exploration
AbstractThis paper through the exposition of the principle of ultrasonic welding technology and ultrasonic influencing factors of the investigation, analysis of the advantages and disadvantages of ultrasonic welding technology, combined with the author's design practice, explore the Ultrasonic welding technology, the development of ultrasonic welding technology, throw a brick to attract jade, based on ultrasonic welding technology to explore the future application areas.
Keywords ultrasonic; welding technology; industrial products
Ultra-sonic Welding Technology in the Application of Industrial Product Design?s Exploration
HE Jun-hua1 MA Wen-juan2 LV Shuang-shuang3 WENG Mao-hong1 GUAN Jun1 GONG Yun1
(1.School of Engineering, Zhejiang A&F University, Lin?an Zhejiang. 311300, China;
2. School of Agricultural and Food Science, Zhejiang A&F University, Lin?an Zhejiang, 311300, China;
3. School of Landscape Architecture and Architecture, Zhejiang A&F University, Lin?an Zhejiang, 311300, China)
AbstractThe article through to the illustration of the principle of ultra-sonic welding and the affecting factors of ultra-sonic probe, analyzing the advantages and disadvantages of ultra-sonic welding technology, combined with the author?s design practice, explore the development of ultrasonic welding technology, topic and is based on the exploration on the application felid of ultra-sonic welding technology in the future.
Key wordsUltra-sonic; Welding technology. Industrial product
In the production of industrial products, some industrial materials are often used, such as plastic, metal, wood and some other industrial materials. In our daily life, we often see a product not only with a material to produce; we also often see a product by more than one part of the composition, and each part of the gap between them, which not only affects the quality of the product, but also affects the aesthetics of the product. This requires them to be welded to each other. With the development of technology, people have higher and higher requirements for welding technology, the current traditional welding technology is not only high cost, but also the quality of welding is not high, often resulting in small gaps. Therefore, people want to use new welding technology to improve the quality of products.
In 1943, on the basis of summarizing the theory and practice of previous generations, Behl of the United States invented ultrasonic welding, and has since promoted the development of ultrasonic welding technology. Due to the ultrasonic welding technology with energy saving, no need to assemble the smoke dissipation heat dissipation device, welding without welding accessories, low cost, high efficiency, good sealing, easy to realize the advantages of automated production, ultrasonic welding technology is developing more and more quickly.
1 ultrasonic welding technology in the application of industrial products in the status quo
Like in the aerospace, nuclear energy industry, electronics industry, such as some of the high precision requirements of industrial products in the field, the use of traditional welding technology is difficult to meet the technical requirements, but also high cost, low efficiency. At present, ultrasonic welding technology in various industries have a wide range of applications, such as medical machinery, packaging, hardware and other industries; can be welded to a lot of products, such as automotive parts, optical lenses, USB flash drives and so on.
2 Principles and characteristics of ultrasonic welding technology
Ultrasound is a frequency higher than 20,000 Hz sound waves, so the energy is large. Ultrasonic welding is the use of ultrasonic frequency (more than 20,000 Hz) mechanical vibration energy, connecting the same or dissimilar metals, semiconductors, plastics and metal ceramics and other materials, special welding methods [1]. Ultrasonic action on the thermoplastic plastic surface, will produce tens of thousands of times per second of high-frequency vibration, this high-frequency vibration of a certain amplitude, through the upper weldment ultrasonic energy to the weld zone, but also due to the weld zone that is the two welded interface at the acoustic resistance is relatively large, and therefore will produce localized high temperatures. And because of the poor thermal conductivity of plastic products, a moment can not be gathered in time to disperse the energy, so the energy will be gathered in the weld area, resulting in the contact surface of the two plastics quickly melted, plus a certain amount of pressure, it will be fused into one. When the ultrasound stops working, let the pressure continue for a few more seconds, so that it solidifies and molds, so that a solid molecular chain is formed, thus achieving the purpose of welding. In the ultrasonic welding of metal, neither to the workpiece conveying current nor to the workpiece to apply high-temperature heat source, just under the action of static pressure, the elastic vibration energy into the workpiece interface friction work, deformation energy and a limited temperature rise, so that the welding region of the metal atoms are instantly activated, the two-phase interface at the molecular interpenetration, and ultimately realize the solid-state metal weldment connection. Its welding principle schematic shown in Figure 1 [2].
2.1 Advantages of ultrasonic welding technology
Compared with traditional welding technology, ultrasonic welding technology has the following advantages: (1) fast welding speed, high welding precision, high strength of the welded joints; (2) a wide range of welding, good stability, being welded after the deformation of the workpiece is very small; (3) weldments surface is clean and beautiful, flat and smooth; (4) welding, do not need to add Welding agent, the processed material does not produce pollution, does not produce harmful gases, so it is an environmentally friendly welding method; (5) welding, only need to provide a small power can be welded, low energy consumption; (6) simple operation, low cost, high efficiency, good sealing.
Figure 1 Schematic diagram of the principle of ultrasonic metal welding
2.2 Disadvantages of ultrasonic welding technology
Although ultrasonic welding technology has a lot of advantages, but there are also shortcomings, and therefore have to pay attention to. Ultrasonic welding technology has the following shortcomings: (1) the understanding of the ultrasonic welding mechanism is not comprehensive enough; (2) the welding of metal, weldments can not be too thick; (3) the ultrasonic welding technology to the influence of more factors, it is not easy to grasp the analysis and summarize; (4) the manufacture of a number of high-power ultrasonic welding machine cost is high, and is difficult; (5) the welded workpiece after welding the quality of the weld Detection is more difficult, thus bringing obstacles to mass production. 3 factors affecting the quality of ultrasonic welding
Although ultrasonic welding technology has many advantages, but its welding quality and melt, material and other factors related to the generalization of the main factors include the following aspects, as shown in Figure 2.
Figure 2: Factors affecting the quality of ultrasonic welding
(1) Welding material: Generally speaking, the quality of welding is related to the physical properties of the material and the modification of the material. The physical properties of the material include the material's modulus of elasticity, coefficient of friction, thermal conductivity, melting point and so on. The welding quality of an object is directly proportional to the material's modulus of elasticity, coefficient of friction, thermal conductivity, and inversely proportional to its density and melting point. Material modification refers to the addition of some fillers under suitable process conditions to improve the original properties of the material, so that it meets the customer's requirements. In the appropriate process conditions to add some similar properties of the material, you can improve the strength of welded joints.
(2) welding head and the contact surface of the weldment: the cleanliness of the welding surface, the roughness of the surface of the material will affect the welding quality of the weldment. Increase the surface roughness of the material can improve the welding quality; the higher the cleanliness of the welding surface, the higher the welding quality.
(3) other factors: the process parameters of welding technology, the structure of the weldment, the form of connection, the amount of melt during welding, ultrasonic power, etc.. In order to achieve the best welding effect, in the product development stage, these factors should be considered comprehensively.
4 ultrasonic welding technology in industrial product design application case
As mentioned above, based on the ultrasonic welding technology product development, the first comprehensive consideration of factors affecting the quality of welding, and then combined with the product's market prospects, the cost of the product, the production of technical requirements, such as the conditions of the production of reasonable production design elements.
The following is only a design case - the United States Apple invented the ultrasonic plastic and metal welding patented technology for interpretation, from the practical point of view to understand the application of ultrasonic welding technology in practice. Insufficiency of the original technology: Before the invention of this patented technology, all portable devices (such as cell phones) can not be fused with metal and plastic, so some parts can not be replaced by plastic parts, so that the production of cell phones is not only heavy, dull and lack of personality, the design is not enough freedom, lack of flexibility. Moreover, the production cost is high, the operation is complicated, it is not convenient to use, and the contact will not work when too many buttons are operated. Solution: Adopting the new ultrasonic plastic and metal welding technology, using plastic material for some parts inside the cell phone, which reduces the weight of the cell phone and also reduces the amount of metal used. In the case of the shell using a molding process, so that the shell is more simple, smooth, easy to operate, flexible design, giving people a high-end, atmospheric feeling. Advanced ultrasonic welding technology generally also need to use a variety of materials fusion technology process, the design is more free and flexible, the design lines using a minimalist style, the use of light colors on the color, giving people a relaxed, pleasant feeling. In the structure more in line with the working principle of ultrasonic welding, so that the welding quality is better.
5 Conclusions and prospects for the application of ultrasonic welding technology for the case
Through this research, the authors through the understanding of ultrasonic welding technology, ultrasonic welding technology application research, due to the limited conditions, there are still deficiencies in the investigation and research process, here will be in the process of the research involved in the problem and the solution to summarize, for the back of the further research Do pave the way. For the problem of welding quality, we conclude that the contact surface should be kept clean and the roughness of the material surface during welding. To understand the needs of users, design for specific users, design a variety of different appearance form, tailored for different customers; in the design should also consider the problem of amorous, design a more amorous products, to create a relaxing and pleasant environment. For ultrasonic welding technology in product design prospects, the authors after exploration found that you can work to increase the music playback function, so that the welding process is relaxed and enjoyable. The future of ultrasonic welding technology will also be more humanized.
References
[1] Guan Changshi, Fei Yushi. Ultrasonic welding principle and practice[J]. Mechanical Design and Manufacturing, 2004(6).
[2]Zhu Zhengqiang, Wu Zonghui, Fan Jinghui. Research status and prospect of ultrasonic metal welding[J]. Welding Technology, 2010, 39(12).