Ultrasonic welding

Summary

Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld. It is commonly used for plastics and metals, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. When used to join metals, the temperature stays well below the melting point of the involved materials, preventing any unwanted properties which may arise from high temperature exposure of the metal. History Practical application of ultrasonic welding for rigid plastics was completed in the 1960s. At this point only hard plastics could be welded. The patent for the ultrasonic method for welding rigid thermoplastic parts was awarded to Robert Soloff and Seymour Linsley in 1965. Soloff, the founder of Sonics & Materials Inc., was a lab manager at Branson

Official source

https://en.wikipedia.org/wiki/Ultrasonic_welding

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Progress on Tests on Splices Between Nb3Sn Rutherford Cables for Graded High-Field Accelerator Magnets

Pierluigi Bruzzone, Mithlesh Kumar

Future high-field accelerator magnets foresee the extensive use of Nb3Sn, more expensive than the Nb-Ti of LHC. For projects involving the series production of magnets, conductor grading is mandatory in order to reduce the cost. To allow grading, a splice between higher and lower grade cables must be implemented. The internal splice option, i.e., embedded in the winding pack, is the one considered in this manuscript. The magnet technology is Wind & React (W & R). The target resistance is 1 n at a background field of B & approx;10 T and ratio between operational and critical current IIc& approx;13, the one at which such Nb3Sn dipoles are expected to work. This manuscript reports progress on ultrasonically welded, soldered and diffusion-bonded splices. The feasibility studies on ultrasonic welding between Nb3Sn Rutherford cables and strands is presented. The potential corrosive effect of fluxing agents of impregnated soldered samples is examined. In the end, the design and test in SULTAN of bent diffusion-bonded splices is reported.

IEEE-INST ELECTRICAL ELECTRONICS ENGINEERS INC2021

Microfluidic connectors by ultrasonic welding

Nico de Rooij

We attempted ultrasonic welding as a technique for the bonding of connectors to microfluidic devices. Different schemes of the method were explored based on different designs of the connectors to achieve a strong, minimal dead-volume connection. Results showed that without the use of inserts, there would be unwanted flow of melt material into the conduit of the connector causing blockage. With the small scale of welding, the use of inserts and proper fixture designs were necessary to block or direct melt flow during the process. The process times were well within 1 s. Two connectors were also simultaneously welded on a microfluidic device to demonstrate the possibility of further increase in productivity in the technique. The device was able to withstand a minimum of 6 bars (gauge) pressure. Where dead-volume is not a concern, it was possible to create connection without the use of an insert by employing different connector geometry and changing the scheme of the welding. It was found out that the width of the welding zone is limited by the width of the sleeve (application of ultrasonic energy to the connector). Hence, the welding zone would proceed no further towards the conduit and causing blockage.

2009