• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.5
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• pp.570-575
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• 2011

Ultrasonic metal welder is consisted of power supply, transducer, booster, and horn. Precise designing is required since each parts' shape, length and mass can affect driving frequency and vibration mode. This paper analyzed Cu sheet deposition characteristics using ultrasonic metal welder and tension tester. A horn suitable for 40,000Hz was attached to the ultrasonic metal welder in order to weld Cu plates. The Cu sheet welding was done with different amplitude, pressure, and welding time, and its maximum tension was measured with tension tester. Maximum tension of 153.87N was obtained when the pressure was 2.0bar, amplitude was 80%, and welding time was 0.30s. Therefore, excessive welding condition negatively influences maximum tension measurement result.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.2
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• pp.66-72
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• 2012

Ultrasonic metal welder is consisted of power supply, transducer, booster, and horn. Precise designing is required since each part's shape, length and mass can affect driving frequency and vibration mode. This paper gives a description of an experimental study of the ultrasonic welding of metals. A horn suitable for 40,000Hz was attached to the ultrasonic metal welder in order to weld Cu sheet. The Cu sheet welding was done with different amplitude, pressure and welding time, and its maximum tension was measured. Maximum tension of 177.99N was obtained when the pressure was 2.5bar, amplitude was 80%, and welding time was 0.34sec. Therefore, excessive welding condition negatively influences maximum tension measurement result.

• Journal of IKEEE
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• v.22 no.1
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• pp.201-204
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• 2018

We know that the piezoelectric constant d, the dielectric constant, and the electric-mechanical coupling coefficient affect the output for piezoelectric ceramics used in ultrasonic welders. Therefore, in this study, the characteristics of ceramics according to the changes of additives to the components of PZT-PMN-PZW were examined. When the addition amount of $MnO_2$ was 2 wt%, the most excellent properties were shown, which suggested the applicability as a material for fusion welding.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2008.11a
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• pp.339-340
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• 2008

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.2
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• pp.282-287
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• 2010

This paper gives a description of an experimental study of the ultrasonic welding of metals. In ultrasonic metal welding, high frequency vibrations are combined with pressure to join two materials together quickly and securely, without producing significant amount of heat. Ultrasonic metal welder consists of Transducer, Booster, and horn that are designed very accurately to get the natural frequencies and vibration mode. In this study, The horn was designed and analyzed the natural frequency by the modal analysis and harmonic analysis. And using a fiber optic sensor, we measured the amplitude and analyzed the Fast Fourier Transformed result. Using the horn, Ultrasonic metal welding between Cu sheet and Cu sheet of 0.1mm thickness was accomplished under the optimal conditions of static pressure 0.15MPa, vibration amplitude 30% and welding time of 0.28s. This result can be used for ultrasonic metal welding in manufacturing industry.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.5
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• pp.419-423
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• 2008

A new polymer replication technology using ultrasonic vibration is proposed and demonstrated. A commercial ultrasonic welder has been used in this experiment. Two different types of nickel molds have been fabricated: pillar type and pore type microstructures. Polymethyl methacrlylate (PMMA) has been used as the replication material and the optimal molding time was 2 sec and 2.5 sec for pillar-type and pore-type micromolds, respectively. Compared with the conventional polymer micromolding techniques, the proposed ultrasonic micromolding technique has the shortest processing time. In addition, only contact area between micromold and polymer substrate is melted so that the thermal shrinkage can be minimized. The fabricated PMMA microstructures have been very accurately replicated without vacuum. The proposed ultrasonic molding technique is a good alternative for high volume production.

• Proceedings of the KIPE Conference
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• 2008.06a
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• pp.164-166
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• 2008

Ultrasonic welder joins with a horn and a booster for amplification of the mechanical displacement. This coupling generates other resonance points at a frequency range lower than the piezoelectric material's resonance frequency. Therefore, frequency variation range through PLL control was proposed in order to prevent reaction to these resonance points.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.2
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• pp.47-52
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• 2010

Miniaturization and lightweight are increasingly the recent trend in the manufacture of electric appliances and machine parts. So technology of micro joining for joining materials is indispensable. This paper gives a description of an experimental study of the ultrasonic welding of metals. In ultrasonic metal welding, high frequency vibrations are combined with pressure to join two materials together quickly and securely, without producing significant amount of heat. Ultrasonic metal welder consists of Transducer, Booster, and Horn that are designed very accurately to get the natural frequencies and vibration mode. In this study, The horn was designed and analyzed the natural frequency by the modal analysis and harmonic analysis. And using a fiber optic sensor, we measured the amplitude and analyzed the Fast Fourier Transformed result. Using the horn, Ultrasonic metal welding between Ni sheet and Ni sheet of 0.1mm thickness was accomplished under the optimal conditions of static pressure 0.15MPa, vibration amplitude 45% and welding time of 0.28s. This result can be used for ultrasonic metal welding in manufacturing industry.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.26 no.4
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• pp.425-429
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• 2017

During ultrasonic welding, plastic deformation, elastic hysteresis, and friction generate heat at the contact portions of the two materials to be welded, theoretically analyzing and experimentally measuring the temperature at the welded part are very important for identifying the heat affected zone. However, the welding temperature during ultrasonic welding wherein welding is performed in less than a second is a challenge. We investigated the effects of welding conditions such as welding time, welding pressure, and the ultrasonic vibration amplitude of horns on the temperature of welded surface of a Ni sheet of thickness 0.1 mm. We used a horn with a resonance frequency of 40 kHz and an ultrasonic welder. The temperature was measured using a intrared sensor, and its characteristics were investigated. Experimental results showed that increase in welding time and pressure and ultrasonic vibration amplitude of horns generally caused the increase in surface temperature of the weld.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.1
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• pp.76-81
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• 2012

Ultrasonic metal welding is one of the welding methods which welds metal by applying high frequency vibrational energy into specific area at constant pressure, avaliable in room temperature and low temperature. Ultrasonic metal welder is consisted of power supply, transducer, booster, and horn. Precise designing is required since each parts' shape, length and mass can affect driving frequency and vibration mode. This paper focused to horn design, its length L was set to 62mm by calculating vibration equation. By performing modal analysis with various shape variable b times integer, when length of b is 30mm the output was 39,599Hz at 10th mode. Also by performing harmonic response analysis, the frequency response result was 39,533Hz, which was similar to modal analysis result. In order to observe the designed horn's performance, about 4,000 voltage data was obtained from a light sensor and was analyzed by FFT analysis using Origin Tool. The result RMS amplitude was approximately 8.5${\mu}m$ at 40,000Hz, and maximum amplitude was 12.3${\mu}m$. Therefore, it was verified that the ultrasonic metal welding horn was optimally designed.