One. Principles of Ultrasonic Welding
It operates based on the principle of ultrasonic energy. High-frequency vibration generates dynamic shear stress at the contact point of the two workpieces. The resulting frictional force will cause local plastic deformation and heat, thereby forming a bond at the interface.
Two. Equipment Introduction
1. Power supply: Provides high-frequency and high-voltage current for the transducer.
2.Transducer: Converts electrical signals into high-frequency mechanical vibrations (using piezoelectric crystals).
3.Turbocharger and amplitude transformer (ultrasonic generator) : The turbocharger amplifies the vibration, and the amplitude transformer transmits it to the welded plate.
4.Fixture/clamping device: It uses pneumatic, hydraulic or mechanical force to fix the workpiece in place.
Three. Work Process
1.High-frequency current passes through the piezoelectric transducer and is converted into mechanical vibration.
2.The supercharger amplifies these vibrations.
3.The amplitude transformer transmits vibration to the workpiece under moderate pressure.
4.Shear force and frictional force cause plastic deformation and local heating at the interface.
5.A strong joint can be formed without melting the material or using filler metal.
Advantages and disadvantages
✅ Advantages：
It is easy to automate and has a fast production speed
High-strength joints can be formed without external heating
The process is clean and the surface finish is high
Applicable to dissimilar metals (such as copper and aluminum)
There is no molten metal splashing
❌ Disadvantages：
Limited to thin and soft metals (such as aluminium, with a maximum thickness of approximately 2.5 millimeters)
The mold cost of custom fixtures
Vibration may damage electronic components
Practical application
Nuclear reactor: Component manufacturing
Automobiles: key chains, headlight components, switches
Electronics: Armature winding, circuit breaker
Medical: Filters, masks (cleaning, precision welding)
This article covers the principle, working principle, equipment, applications, as well as advantages and disadvantages of ultrasonic welding. If you have any questions, please ask them in the comment section! Don't forget to share this article on your social network.