Acoustic Horn Design and Effects of Process Parameters on Properties of Dissimilar Ultrasonic Welding Aluminum to Brass

Abstract

Ultrasonic welding technology is the new and emerging concept, which can be applied to many industrial applications. The vital part of this technology is the horn, which acts as a tool, upon which the pressure and high frequency vibration is applied to create a solidstate weld. In this study, a special type of horn is designed and its length is determined analytically. Dimensions obtained by finite element method (FEM) are employed for the horn used in the present experiments to weld brass with aluminium sheet of thickness 0.1 mm. The dynamic analysis is also performed to find out the stress and amplitude distribution in the horn under loading conditions. Welding has been carried out using various parameter combinations in order to improvise the weld strength. Maximum weld strength of 4.05 MPa is obtained under the optimum welding conditions of 0.21 sec weld time, 0.26 MPa weld pressure and 60µm vibration amplitude. The microhardness test also has been done on the optimized results to show the plastic flow at the weld zone. It confirms that the hardness of both materials up to 20µm distance around the weld zone is increased with respect to the parent materials.

Power consumption and friction coefficient in the ultrasonic consolidation of aluminium alloys

“…Besides the traditional applications in similar material manufacturing, UC can also be used in the bond of dissimilar materials and forming of fibre-reinforced metal matrix composite. [1][2][3][4][5][6][7] Although the effects of welding parameters on the bond quality of UC have been widely studied, [8][9][10][11][12][13][14][15] some issues are still not fully understood. There are two major challenges on the bond quality control of UC.…”

“…The average power consumptions under the different building heights of two cases. Note: F, v and A are the applied force, travel speed and oscillation amplitude, respectively5 The average relative levels under the different building heights of AA-2024 and AA-70756 The relationships between the calculated and experimental power consumptions7 The relationships between the power-calculated and linecontact-tested friction coefficients. Note: A and T are the oscillation amplitude in the UC set experiment and preheating temperature in the line-contact friction test, respectively…”

Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

“…This indicated that attaching and not attaching the transducer with ultrasonic horn would not have significant influence on the correctness of finite element analysis results. Therefore, numerous researchers considered ultrasonic horns only for carrying out modal and harmonic analysis [6,7,13,15,19,20,25,29,33,36,40,41,48,49,55,57].…”

“…3 rd order Bezier horn has been suggested by designers for higher vibration amplification as compared to other standard ultrasonic horn designs except step horn, and low stresses due to smooth variation in cross sectional area [12,25]. Stress concentrations can be reduced by incorporating smooth curves at the location of abrupt change in cross section [19,[26][27][28][29][30]. However it may cause reduction in amplitude of vibration as well [7].…”

Design and performance analysis of ultrasonic horn with a longitudinally changing rectangular cross section for USM using finite element analysis

“…A new design was developed, comprising of conical horn profile at the upper end and a cylindrical profile at the lower end, which yields a maximum magnification factor for higher MRR and safe working stress on the horn domain. Satpathy et al [7] designed a special type of acoustic horn and determined its length analytically. The designed horn was used during the process of welding brass and aluminum sheets of thickness 0.1 mm.…”