intro

ultrasonic welding for metals, has received significant research and there have been advances in the technology. Because of these advances, the process has been developed into a practical production tool. Although the ultrasonic metal welding has many advantages including speed, efficiency, long tool life, there are several issues. For example, tool/part adhesion (sticking), part marking and the lack of the consistency and predictability of the weld strength are issues that industry currently encounters with ultrasonic metal welding. To resolve these issues of the ultrasonic metal welding process, various experiments have been conducted on aluminum 5754 alloy samples. These experiments included replacing a constant amplitude with amplitude profiling and placing buffer sheets of copper and zinc between the tool (horn) and the top part prior to ultrasonic welding. In addition, experiments were conducted to compare the consistency of weld strength for the three control modes: energy, height (post height), and time. Their results were analyzed and compared in terms of weld strength, weld consistency and weld quality.

ABSTRACT
In this paper an effective methodology is developed to determine the optimum welding conditions that maximize the strengthof joints produced by ultrasonic welding by.

Abstract
In ultrasonic welding, high frequency vibrations are combined with pressure to join two materials together quickly and securely, without producing significant amount of heat. During ultrasonic welding of sheet metal, normal and shear forces act on the parts to be welded and the weld interface. These forces are the result of ultrasonic vibrations of the tool, pressed onto the parts to be welded. In this study a model for the temperature distribution during welding are presented. With the knowledge of the forces that act at the interface it is possible to control weld strength and avoid sonotrode welding (sticking of the sonotrode to the parts). The presented finite element model is capable of predicting the interface temperature during welding and their influences in the work piece, sonotrode and anvil. The study also included the effect of clamping forces, material thickness and coefficient of friction during heat generation at the weld interface.

Abstract
Ultrasonic welding process is a rapid manufacturing process used to weld thin layers of metal at low temperatures and low energy consumption. Experimental results have shown that ultrasonic welding is a combination of both surface (friction) and volume (plasticity) softening effects. In

the presented work, a very first attempt has been made to simulate the ultrasonic welding of metals by taking into account both of these effects (surface and volume). A phenomenological material model has been proposed which incorporates these two effects (i.e. surface and volume). The thermal softening due to friction and ultrasonic (acoustic) softening has been included in the proposed material model. For surface effects a friction law with variable coefficient of friction dependent upon contact pressure, slip, temperature and number of cycles has been derived from experimental friction tests. Thermomechanical analyses of ultrasonic welding of aluminium alloy have been performed. The effects of ultrasonic welding process parameters, such as applied load, amplitude of ultrasonic vibration, and velocity of welding sonotrode on the friction work at the weld interface are being analyzed. The change in the friction work at the weld interface has been explained on the basis of softening (thermal and acoustic) of the specimen during the ultrasonic welding process. In the end, a comparison between experimental and simulated results has been presented showing a good agreement.

Abstract
According to our proposed weld method and apparatus, the welding conditions and strengths between heterogeneous materials of polymethyl-methacrylate (PMMA) and ductile polycarbonate (PC) have been studied. The functional gradient interposed sheet (IPS) prepared from three layers is valid for weld according to its excellent mechanics properties. Excessively long welding time has brought IPS cracking and air bubbles at local part of interfaces. Weld under higher welding stress can enlarge the welding areas and remove air bubbles so as to enhance the strength. Therefore, enlarging welding areas and reducing the air bubbles are very important to improve the welding strengths. The effective welding conditions are the shorter welding time and higher welding stress. According to our study, the novel welding method is effective for heterogeneous materials weld

. The thermo-mechanical analysis of an ultrasonic spot welding process was performed using

developed finite element models. Temperaturetime histories of aluminium specimens during welding were successfully obtained from the analysis and validated by physical tests. It was shown that the effect of frictional heating on the plastic deformation of aluminium during ultrasonic spot welding was significant and should be included in the analysis of the welding process in order to achieve good correlation with the physical phenomenon.