 In 1938, Lludwig Bergman and some colleagues were experimenting

with ultrasonic Waves and their effects on metal. He found that many
metals could be combined by using ultrasonic welding that could not
be joined by any other method.

 The ultrasonic effect upon the molten metal generates a smaller grain
size, giving the metal more strength. Ultrasonic welding combines
pressure and high frequency vibration motions to form a solid state
bond.

 The range ultrasonic frequency used in this welding is from 20kHz to

60kHz. This cool, strong weld capable of joining such combination as
alIuminium to steel, alIuminium to tungsten, alIuminium to
molybdenum and nickel to brass.
 Ultrasonic metal welding Ultrasonic metal welding is a
technique suitable for joining both similar and dissimilar metal
work pieces or welding a piece of metal to a metalized
substrate(ceramics or glass).

 The weld formation is caused by the application of external

pressure and ultrasonic vibrations.

 In order to give a general idea of the technique a

short description is given of the fundamental parts
of the welding equipment and the parameters
involved.

 This is followed by a list of special characteristics of the

process and finally some fields of application are mentioned.
 It consists of an ultrasonic generator, which generates a frequency of 20
kHz to 40 kHz from a supply of 220v/50Hz.

 The converter transforms the high frequency electric energy produced

by the generator into mechanical energy.

 The booster serves as an amplitude transformer for the required

amplitude range as well as a general stabilizer for the oscillations of the
transducer system. The sonotrode or horn is the working tool of the
ultrasonic metal welding.

 The pieces to be welded are clamped between the welding tip called
sonotrode and anvil. Both tip and anvil are faced with high-speed steel,
since considerable wear can occur at the contacting surface.

 The process of ultrasonic welding is fairly simple. It begins when the

parts those are to be welded, such as two multi-strand copper wires for
example, are placed together in the welding unit.
 The system that is used to scrub the pieces together consists of four
major components. The first of these is the anvil. This is simply a piece of
the machine, usually with a replaceable head, that holds one of the
components still while the other is rubbed against it.

 The "business end" of the ultrasonic system consists of three major

parts. The first of these is the ultrasonic transducer.

 This component takes an electric signal from a power supply that is

providing a 20 kHz AC (by using an ultrasonic generator) signal and
converts it to a mechanical motion at the same frequency.

 The vibration that results is at a frequency that is appreciably above the

range of human hearing, hence the name ultrasonic.

 This motion is then passed into the ultra sonic horn. This is the portion
of the system that actually vibrates the work piece. In addition to
providing the interface between the ultra sonic generator and the work
piece, the horn also further amplifies the amplitude of the motion, again
reducing its force
 Heat affected zone is minimized
 Very thin materials can be welded
 Surface deformation is minimum
 Welding of glass is also possible
 No defects due to gases, arc and filler metal
 Equipment is simple and moderate skill is enough
 Dissimilar materials can be joined
 Restricted to join thin materials
 Competitively not economical
 Materials being welded may tend to weld to the
tip and anvil