ultrasonic welding

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ultrasonic welding

[¦əl·trə′sän·ik ′weld·iŋ]
A nonfusion welding process in which the atomic movement required for coalescence is stimulated by ultrasonic vibrations.

Welding, Ultrasonic


a method of welding that uses ultrasound to transmit vibrations to a tool clamped to the surfaces of the materials being welded.

Metals are welded in the solid phase, without melting. A metal is heated to 200°–600°C by friction between the tool and the metal. The vibrations of the tool promote surface cleaning, and the resulting weld is therefore of good quality.

Ultrasonic welding is used primarily to join sheet metals (such as Al, Ti, and Cu), certain alloys, and plastics at individual spots or along continuous seams. The thickness of the sheets is 0.1–2 mm. The welding time for spot welding is 0.1–5.0 sec when the clamping force of the tool is 20–200 kilograms-force (0.2–2 kilonewtons).

When workpieces with different thicknesses are welded, one workpiece should be thin, that is, not thicker than 1 mm, but the other may be as thick as desired.

The equipment employed for ultrasonic welding includes a high-frequency electron-tube oscillator with a power output of 0.5–5 kilowatts and a magnetostrictive transducer with a core whose length may be varied. The core is coupled to a wave-guide acoustic intensifier that supports a force-application device with a hard-alloy tip. Ultrasonic welding is used primarily in the radio-engineering, electronic, and electrical-engineering industries.


Silin, L. L., G. F. Balandin, and M. G. Kogan. Ul’trazvukovaia svarka. Moscow, 1962.
See also references under .


ultrasonic welding

A solid-state welding process in which the metals are joined by the local application of high-frequency sound waves as the work parts are held together under pressure.

ultrasonic welding

The bonding of materials, typically made of plastic, by pressing them together and vibrating them at ultrasonic speeds for a fraction of a second. It is a very fast, very clean way to combine objects together. First used to bond toy parts in the 1960s and widely used in the automobile industry starting in the 1980s, ultrasonic welding is used to weld myriad plastic elements together. See ultrasonic.

Bonding Plastic Parts
In this example, the two plastic parts are placed into the chamber, and the head is pressed down. The welding operation takes a fraction of a second.
References in periodicals archive ?
For each application, the horn is designed to combine with the other stack components to reach the optimum level of amplitude output to allow ultrasonic welding to occur as efficiently as possible.
Experimental studies on optimization of process parameters and finite element analysis of temperature and stress distribution on joining of Al-Al and Al-Al2O3 using ultrasonic welding, The International Journal of Advanced Manufacturing Technology, 55(5): 631-640.
3 mm were welded with impulse welding and ultrasonic welding.
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The plastic materials with good ultrasonic welding proprieties are: PP (polypropylene), PVC (vinyl polychloride) etc, for which 0,35<[beta]<0,55 [cm.
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Tennex uses Branson ultrasonic welding equipment at all their sites including those in Japan and the UK, which enables it to exchange readily and smoothly machine settings and other critical welding information within its global network.
An energy director is widely used in ultrasonic welding to increase the welding speed and quality.
Ultrasonic welding has been successful in sections up to 40-mils (approximately 1mm) thick.
In addition, several newer processes are being spotlighted as promising solutions, including magnetic pulse welding and a new high-power ultrasonic welding that opens the door for use in heavier gages.
The Society of Plastics Engineers (SPE) Detroit Chapter recognized Magna for its innovative use of laser cutting and welding the fascias instead of punch and ultrasonic welding, which provides greater flexibility for lower-volume parts.

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