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Ultrasonic Metal Welding is a green manufacturing technique and one of the most advanced solid state welding processes in which similar or dissimilar metallic components are joined by the application of high frequency vibrations (> 20 kHz) and pressure. Ultrasonic metal welding is accompanied by slip and plastic deformation so that the base metals being welded will not melt and in turn forms a homogenous coalescence of two metals at the joining area so that the joint retains the parent metal properties. The major problem faced by the industries using ultrasonic metal welding process is the poor weld quality and weld strength. The design of acoustic horn or sonotrode plays a dominant role in producing quality welds. The primary function of sonotrode is to vibrate at a level required for welding and also to transmit the vibration energy to the point where welding of metals takes place. For producing quality welds, the vibration energy is to be transmitted to the weld interface without much loss. Therefore, there is a need for accurate design of sonotrodes in ultrasonic metal welding process. This work focuses on designing a stepped sonotrode used for joining metallic wire with metallic sheet based on significant design parameters such as amplitude gain and von Mises stress factor using modal and harmonic analysis. Experimental trials are conducted using the stepped sonotrodes and the effectiveness of the designed sonotrodes is evaluated based on improvement of strength of the joint in tension.

Acoustic horn design for joining metallic wire with flat metallic sheet by ultrasonic vibrations