Studies on Continuous Ultrasonic Butt Welding

对大型焊接试样的连续超声对接焊接进行了研究。本工作的目的还包括研制高功率超声振动源、大容量功率放大器以及这些系统所需的控制技术。高功率超声振源设计了6 ~ 8个螺栓夹紧的朗之万型PZT换能器（BLT），采用径向到纵向的振动方向变换器积累，用于对接焊接的各种高功率超声振源。设计了以下几种超声波振动源，并应用于焊接；(1)采用6个BLT换能器的27 kHz振动源。(2) 19 kHz振动源采用8个BLT换能器。(3) 15khz振动源采用8个BLT换能器，具有150%的19khz系统振动能力。(4) 15 kHz振动源采用8个新设计的直径为70 mm的BLT换能器，其容量约为直径为50 mm换能器的15 kHz的200%。设计了采用大容量振动系统的超声波对接焊接系统，并对其焊接特性进行了研究。2 .将厚度为6 ~ 10mm的铝板、防腐铝板和铜板试样成功地端对端连接，焊接强度与试样接近。大容量超声功率放大器采用新开发的50kw和100kw的静态感应晶闸管，设计了大容量大功率超声固态功率放大器，用于驱动焊接系统。研究了功率放大器与超声振源的匹配及功率因数补偿。焊接条件的检测通过检测焊接过程中的声信号以及通过和从焊件中发出的声信号光谱，研究了焊接过程中焊接条件的检测方法。这种方法也被发现有效的超声线键合IC或lsi。大型焊接试件的连接采用一定距离驱动试件，焊接强度均匀的方法对宽板试件进行连接试验。采用大容量振动源和功率放大器的连续焊接系统是目前研究的热点。少

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