Evaluation of Vibration Amplitude Stepping and Welding Performance of 20 kHz and 40 kHz Ultrasonic Power of Metal Welding

Today ultrasonic power technique is consider amandatory technique which is always entered in many processessuch as in metal and plastic welding to overcomes many issues,with aided of applying force (pressure) and supplied highfrequency vibration, a solid-state weld can be generated byultrasonic metal welding technique. That give a technique theability to join not only a small components, whereas also to jointhicker specimens, depend on a proper control of matchingwelding conditions. Therefore a welding performance can bestudy and compared after designed welding horn to resonance atfrequencies of 20 kHz and 40 kHz. The analyses of the designedhorn are completed through use a vibration mathematicalexpressions, modal and harmonic analyses to ensure theweldability due to applying ultrasonic power to the working areaand also to compare the performance of joint at using tworesonance frequencies of 20 kHz and 40 kHz. The dimensions ofthe horns were determined to match the selected resonancefrequencies, which the lengths were calculated as 132 mm and 66mm respectively. The analysis of the exciting modal indicates thatthe axial vibration modes of 19,584Hz and 39,794Hz are obtainedin 10th mode, while the two frequency values are recorded 19,600Hz and 39,800 Hz from the frequency response of the two horns.The weld strength between Al and Cu specimens with a thickness0.5 mm were evaluated using tensile test, which the analyses wereobtained under using different welding pressure and variedamplitudes. The results were recorded within exciting a horn withtwo different resonance frequencies, show the enhancement ofweld strength and quality through control of stepping amplitude,the enhancement means obtain good strength of the weld, reducesticking horn to specimen, and lower specimen marking