New methods of ultrasonic welding of metal and plastic materials

Abstract

New ultrasonic welding methods of metal and plastic materials have been proposed by the author and have shown their effectiveness. For welding of thick and large metal specimens, (1) an ultrasonic butt welding method of joining thick metal specimens end to end is proposed. Large capacity vibration sources and solid-state power amplifiers of 50, 100 kW have been developed. (2) The welding method of using two vibration systems crossed at a right angle is effective, and 10 mm thick aluminum plates have been joined successfully. For medium size metal welding specimens, (3) complex vibration welding tips have been shown to be very effective, and one-dimensional complex vibration systems are developed to simplify the systems. For welding of small metal specimens, (4) higher vibration frequency, and complex vibration wire bonding systems are proposed and it is shown that they are significantly effective. Bonding systems of 60 to 600 kHz have been designed. For welding of plastic materials, (5) high frequency and two-vibration-system welding methods are effective.