Studies on Ultrasonic Continuous Seam Welding System Using Complex Vibration

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Conventional ultrasonic seam welding systems using linear vibration locus are available to weld only metal foils and thin metal plates and also it is very difficult to weld multiple continuous welding parts. Using the welding systems with the complex vibration welding tips vibrating in elliptical or circular locus, and square or rectangular locus, it is possible to weld thick metal plate specimens at multiple parts.The welding characteristics of aluminum-aluminum, aluminum-copper and copper-copper plate specimens using the 27 kHz and 19 kHz ultrasonic welding system with a circular disk complex-vibration welding tip were studied. The welding tip part vibrates in an elliptical or circular locus. The seam welding system uses a rotating circular disk welding tip and a shifting stage for continuous welding of the metal sheets. The upper specimens are 0.3-mm- to 0.9-mm-mm thick plates and the lower specimens are 2.0-mm- to-10 mm-thick plates. Using the complex-vibration system, these metal plate specimens of various thicknesses can be welded continuously at multiple positions with large and uniform welded areas and large weld strengths independently of the welding position and direction. The required complex-vibration amplitude is less than one-half of that of a conventional linear-vibration system. The required vibration amplitude for aluminum specimens is more than 3 _m (peak-to-zero value) using the 27 kHz welding system. Aluminum-aluminum, aluminum-copper and copper-copper plate specimens were welded with weld strengths almost equal to the specimen strength using the 19 kHz system under vibration amplitudes of more than 4, 6 and 8 _m, respectively.