Studies on Continuous Ultrasonic Butt Welding

点击翻译按钮获取中文摘要

Continuous ultrasonic butt welding which requires high power ultrasonic systems is studied for joining large welding specimens. The purpose of this work also includes to develop high power ultrasonic vibration sources, large capacity power amplifiers, controlling techniques of these systems which are required for high power ultrasonics.1. High power ultrasonic vibration sourceVarious high power capacity ultrasonic vibration sources for butt welding were designed which has 6 to 8 bolt-clamped Langevin type PZT transducers (BLT) accumulated using a radial to longitudinal vibration direction converter. The ultrasonic vibration sources as follows were designed and used for welding ;(1) 27 kHz vibration source using six BLT transducers. (2) 19 kHz vibration source using eight BLT transducers. (3) 15 kHz vibration source using eight BLT transducers which has 150% vibration capacity of 19 kHz system. (4) 15 kHz vibration source using eight newly designed BLT transducers of 70 mm diameter whic … More h has about 200% capacity of 15 kHz one with transducers of 50 mm diameter.2. Ultrasonic butt welding systemUltrasonic butt welding systems using one large capacity vibration system were designed and welding characteristics of these systems were studied. Aluminum, anticorrosive aluminum and copper Plate specimens of 6 to 10 mm thickness were successfully joined end to end with weld strength nearly equal to specimen.3. Large capacity ultrasonic power amplifierLarge power capacity solid-state power amplifiers for high power ultrasonics using newly developed static induction thyristors with 50 kW and 100 kW output power capacity were designed and used for driving the welding systems.4. Matching and power factor compensation of power amplifier and ultrasonic vibration source were studied.5. Detection of welding conditionDetection of welding condition during welding process were studied by detecting acoustic signals and these spectra through and from the weldment. This method was found effective also for ultrasonic wire bonding of IC or LSI.6. Joining of large welding specimensJoining of wide plate specimens was tried by driving specimens at certain distance and the specimen joined with uniform welding strength. Continuous welding systems using large capacity vibration source and power amplifier are investigating now continuously. Less