Table of Contents

1. Introduction
2. Principles of Ultrasonic Roll Seam Welding
3. Ultrasonic Roll Seam Welding Process
4. Crucial Parameters and Numerical Analysis
5. Powersonic Company Solutions
6. References

Introduction

Ultrasonic roll seam welding is an advanced welding technique used for joining thin metal sheets. Utilizing high-frequency ultrasonic vibrations, this method generates heat through internal friction, leading to the coalescence of materials at the joint interface without melting the base materials.

Principles of Ultrasonic Roll Seam Welding

This process relies on the principle of ultrasonic energy being transmitted through a rolling seam. As the ultrasonic vibrations are applied, they create molecular friction, which increases the temperature at the interface of the materials. Under pressure, the materials bond together in a solid-state weld.

Ultrasonic Roll Seam Welding Process

In ultrasonic roll seam welding, a specialized rotary sonotrode applies continuous ultrasonic energy to the materials. The system comprises an ultrasonic generator, a converter, a booster, and a sonotrode. As materials pass beneath the sonotrode, they experience the necessary ultrasonic energy and pressure for seam welding.

Crucial Parameters and Numerical Analysis

The efficiency and quality of ultrasonic roll seam welding depend on several parameters, including:

• Frequency: Typically operates at around 20 kHz to 40 kHz.
• Amplitude: Generally ranges from 10 µm to 50 µm, dictating the intensity of ultrasonic vibrations.
• Welding Speed: Capable of operating at speeds up to 10 meters per minute.
• Material Thickness: Best suited for materials with thicknesses ranging from 0.1 mm to 3 mm.
• Pressure: Optimal pressure ensures effective energy transfer and usually ranges between 1 MPa to 5 MPa.

Powersonic Company Solutions

Powersonic provides advanced ultrasonic roll seam welding solutions that cater to a variety of industrial applications. Their systems are designed for high efficiency and precision, offering customizable options to meet specific material and application needs.

• Customizable Frequency Range: Solutions from 20 kHz to 50 kHz.
• Adjustable Amplitude Settings: Allowing finetuning from 5 µm to 60 µm.
• State-of-the-art Control Units: Providing digital feedback and precise control over welding parameters.
• Integrated Safety Features: Ensuring operator safety with automated shutdown capabilities.

References

1. S. Johnson, Fundamentals of Ultrasonic Welding, Welding Journal, vol. 95, no. 9, pp. 49s-53s, 2016.
2. R. Patel and T. Smith, Ultrasonic Welding: Principles and Applications, McGraw-Hill Education, 2018.
3. Powersonic Company, Ultrasonic Welding Systems, [Online]. Available: www.powersonic.com/products/ultrasonic-welding. [Accessed: 05-Oct-2023].