Welding by distance allows components to be joined by a specific weld depth. Manual ultrasonic inspection of thin metal welds 1. On optimization of some parameters in ultrasonic metal welding. Ultrasonic testing of welds to api rp 2x tky joints ultrasonic applications, level ii c course covering tky weld examination per api rp 2x.
Ultrasonic testing may be carried out by a level 11 operator or by a level i operator under the direct supervision of a level 11 operator. Evaluating the variables that impact ultrasonic testing a thesis presented to the faculty of the graduate school at the university of missouri columbia in partial fulfillment of the requirements for the degree of master of science by daniel wayne. A crest group company joint design for ultrasonic welding. Part of themechanical engineering commons, and themetallurgy commons. The control of parameters can be ensured by suitable design of the welding device and corresponding control software. The basic reason for this choice is the fact that typical production defects tend to be perpendicular to the plate surface or are astype a approach 38 typec approach o i. Nondestructive inspection of adhesive bonds in metal. A study of weld quality in ultrasonic spot welding of similar. Angle beam ultrasonic testing ut is usually specified in design codes and specifications as a primary flaw detection method in the weld joints and materials. A set of appropriate ndt test specimens, as well as the methodology and procedures for their fabrication, were established. Welding times can vary, but the welds can form in as little as 0. The international standard for the manual ultrasonic testing of fusionwelded joints in metallic material bs en 1714 has been withdrawn in 2010 and replaced by bs en iso 17640.
The basic requirement of any ultrasonic joint design is a small, uniform initial contact area. May 31, 2017 ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. The surface to be subject to ultrasonic testing shall be free from any existing lubricants, dirt, residue, rust and sharp edges, so. This written ultrasonic testing procedure contains the elements set forth in section 6, part f and paragraph s3 of annex s of the american welding society standard d1. Artificially created, directed diagnostic wave enters into the tested material and in the case of a defect deviates from its normal propagation. It is a reliable method for detecting mainly flat internal defects such as incomplete root penetration, lack of fusion, etc.
Ultrasonic testing of austenitic stainless steel welds false indications and the cause of their occurence. Proper ultrasonic welding setup can be drastically different when welding cold parts as opposed to welding hot parts. Ultrasonic testing procedure inspection for industry. Table 2 test results for aswelded joints specimen no. The technique, ultrasonic welding, used highfrequency sound waves and pressure to bond metals together and required less energy than conventional welding.
This solidstate welding process can join a wide variety of dissimilar alloys, thintothin. Fatigue test results obtained from welded joints treated by various improvement techniques are given in tables 27 and their associated fatigue curves are illustrated in figs. Optimization of ultrasonic welding parameters for copper. These may include metal to metal glued joints and metal to. Ascan waveform diagrams in different parts of the joint and the corresponding spectrum characteristic curves after fast fourier transform have different characteristics, as shown in fig. This standard is specified to be applied for the testing of fusion welded joints in metallic material of thickness greater than or equal to 8mm and where both the. Standard practice for ultrasonic examination of longitudinal welded pipe and tubing1 this standard is issued under the. Downselect a nondestructive inspection technique that can accurately detectassess kissing or weak bonds. This specification, dealing with ultrasonic welding, was developed by the american welding society aws g1 committee on joining of plastics and composites in response to a plastics industry demand for a reference document. The horn, under pressure from the assembly stand, contacts one. The objective of the present work is to optimize ultrasonic spot welding parameters for joining 3003 aluminum alloy with 304 stainless steel.
Welding was performed at various clamping pressures i. Ultrasonic metal welding ultrasonic metal welding is a technique suitable for joining both similar and dis similar metal work pieces 1. If the weld is not ground flushed the probe shall be controlled such that it faces nearly parallel to the weld body. Ultrasonic testing technology is based on the ability of highfrequency oscillations about 20,000 hz to propagate into the metal and be reflected from surface scratches, voids, and other discontinuities. Ultrasonic metal welding is an effective technique in joining small components, such as in wire bonding, but is also capable of joining thicker sheet, depending on the control of welding conditions. Experience has proven that ultrasonic bonding can create an ultrareliable metallurgical bond using a single pulse lasting a second or less.
The finished welds are tested by liquid penetrant test and leak test pneumatic, hydro or helium. This joining process is utilized in spottype weld ing, ring welding, line welding, and continuousseam welding ref. The design varies with each application and depends on factors such as type of plastic resin to be bonded,part geometry and requirements of the weld. A crest group company joint design for ultrasonic welding 1. Apr 10, 2010 in this work welding parameters like welding pressure, weld time and amplitude of the vibration are considered while producing ultrasonically welded joints of copper whose thickness is 0.
Welding of plastic parts the function of the energy director is to rapidly initiate plasticisation of the joining surface by the concentration of energy. Effect of ultrasonic welding parameters on microstructure and. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary. For spottype welding, the var iables under control of the welding machine operator are tip radius, nor mal load, electric power input to the transducer and weld time. No warm up or cool down time is necessary, unlike other joining processes, such as hotplate welding. They know that ultrasonic welding is a fast,dependable way of joining wire to wire and wires to terminals. Specimen for thermoplastics, but is included for informational purposes only. The stability of the welding process is increased and the effect of the human factor is reduced with rising automation. Ultrasonic welding offers many advantages to assemblers. Welding fundamental\u000b ultrasonic welding\u000b ultrasonic testing\u000b index introduction welding fundamental welding definition weld type weld shapes weld application. If ultrasonic testing is required, it shall be made in accordance with bs en 1714 using reference level to method 1, evaluation reference level 14db 20% dac and testing level b unless determined otherwise by the steelwork contractors responsible welding coordinator. A whole range of welding parameters has an important effect on quality of the resulting welded joint. This mode operates independently of time, energy or power drawn and compensates for any tolerance variation in the moulded components, thus giving the best guarantee that the same amount of material in the joint is melted each time. Ultrasonic welding is an industrial technique whereby highfrequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solidstate weld.
Technical data rinco ultrasonics ag, industriestrasse 4, ch8590 romanshorn 1, tel. This procedure defines the criteria and general requirements to carry out ultrasonic examination on ferritic welded joints. Course includes detailed interpretation of api rp 2x. Any shape or size of the ed can be chosen within certain limits. Ultrasonic testing of butt weld joint by tofd technique boh ac ik michal 1, mi c ian milo s 1, ko na r radoslav 1, hlavat y ivo 2 1 university of z ilina, faculty of mechanical. Kishigami a study has been made into the causes of the false indications sometimes observed upon ultrasonic inspection of austenitic stainless steel welds. Also explore the seminar topics paper on ultrasonic metal welding with abstract or synopsis, documentation on advantages and disadvantages, base paper presentation slides for ieee final year mechanical engineering me or production automobile students for the year 2019 2020. The article discusses various solutions to common problems in ultrasonic welding. Qualification of submerged arc welding consumables and. This inspection may include the root, sidewall, crown, and heataffected zones of a weld. Bs en iso 5817 welding fusionwelded joints in steel, nickel. It offers many advantages, including process reliability and repeatability, lower energy usage than other joining techniques, material savings because there is no need for consumables, such as glue or mechanical fasteners, and labor savings. Tests of welds in ship hull structures for radiographic inspec. Improving fatigue strength of welded joints by ultrasonic impact treatment sougata roy research assistant atlss, lehigh university bethlehem, pa, usa sougata roy, born 1966, received master degree in civil engineering from lehigh university in 2001.
Physics of the ultrasonic welding process springerlink. However at this stage we look at adjustment and set up of the welding equipment, for which the most important factors are amplitude, clamping. The ultrasonic welding technology enables to produce highstrength joints between sheet metal and aluminium foam sandwich afs without melting of the metal or any damage of the foam structure. There are a variety of joint designs possible, each with specific features and advantages. On optimization of some parameters in ultrasonic metal. One of the key factors to successful ultrasonic welding is good component design, in particular the shape of the surfaces to be joined ie the joint design. Welding data and3he chemical compositions of the base metal and of the welding rod in weight % ferrite content 11. Improving fatigue strength of welded joints by ultrasonic. Part of theagriculture commons,bioresource and agricultural engineering commons, and the industrial engineering commons.
Ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. Optimization of ultrasonic welding parameters for copper to. Microelectronic welding fine wire bonding represents the earliest widely used application for ultrasonic metal welding and still accounts for a large volume of industrial. The process of ultrasonic welding of plastics is achieved by applying a vibrating metal tool horn at 90 to the stationery plastic parts which then vibrate. Ongoing manufacture the weak bond samples and evaluate a wide array of candidate ndi methods. Ultrasonic welding component design and weld parameters. Although ultrasonic testing has been widely used for the evaluation of welded joints, it is often very difficult to adequately perform the sheet metal ultrasonic testing. If other modes of joining are used, this size being very small, it may damage the weld. Standard practice for ultrasonic examination of longitudinal. Ring welding a circular tip used on a spot welder may be used to form a ring weld.
Guidebook for the fabrication of nondestructive testing. Ultrasonic welding component design and weld parameters twi. Ultrasonic testing of austenitic stainless steel welds. It notes that using uneven amplitude can be solved by increasing amplitude through the use of a larger ratio booster, and by training employees to match the right material for a given amplitude. Evaluating the variables that impact ultrasonic testing a thesis presented to the faculty of the graduate school at the university of missouri columbia in partial fulfillment of the requirements for the degree of master of science by daniel wayne looten dr. Pdf ultrasonic testing of butt weld joint by tofd technique. Supplement c, ultrasonic testing method, tcla recommended. A study of weld quality in ultrasonic spot welding of. Efficiency evaluation of ultrasonic impact treatment uit. If the worker has no or only limited experience in plastic welding, the welds will probably not hold up to the testing procedures.
It is generally not a good idea to weld cold parts to hot parts. They have recently published a training text and have permitted the use of the method in a re cent circular memorandum. Ultrasonic examination of t, k, y typical weld joints of. An ultrasonic nondestructive testing method for the. Process and quality characterization for ultrasonic welding of lithiumion batteries by seungjae lee a dissertation submitted in partial fulfillment of the requirements for the degree of doctor of philosophy mechanical engineering in the university of michigan 20 doctoral committee. If it will be necessary to test the welds for a project, the tester needs to be qualified. In this work welding parameters like welding pressure, weld time and amplitude of the vibration are considered while producing ultrasonically welded joints of copper whose thickness is 0.
Mar 31, 2014 welding fundamental\u000b ultrasonic welding\u000b ultrasonic testing\u000b index introduction welding fundamental welding definition weld type weld shapes weld application. A new, more cost effective welding method was introduced in the 1940s. Controlling the ultrasonic plastic welding process. Trinity ndt procedure for ultrasonic examination page 5 of 8 6. Develop a written procedure and provide initial training to inspection personnel. Efficiency evaluation of ultrasonic impact treatment uit of. Spot welding joints of specimens are scanned and detected using the ultrasonic testing device. Test method general the procedures given apply to the contact ultrasonic inspection of butt welds.
In this chpater we present original materials obtained as a result of our own investigations of welded joints of copper and other metals, along with the data of other authors. Ultrasonic testing of austenitic stainless steel welds false indications and the cause of their occurence h. Ultrasonic testing of austenitic stainless steel welds false. Supplement c, ultrasonic testing method, tcla recommended practicej american society for nondestructive testing, shall apply. Many factors determine the success of an ultrasonic welding process long before it gets to a welder, most notably component materials and joint design. Technique for inspecriiigbijtildelesmith shear waves. History how it works features standards din en iso 11666 pdf books reader. Ultrasonic cscan detection for stainless steel spot welds. Ultrasonic test inspection free ndt sample procedures. Ultrasonic welding of coextruded polymer film jessica ann riedl iowa state university follow this and additional works at. Nondestructive inspection of adhesive bonds in metalmetal. Ultrasonic testing procedure ultrasonic metal testing ultrasonic inspection.
In the position of nonwelding zone a, since the impedance of the. Effect of ultrasonic welding parameters on microstructure. This study presents the design, characterisation and test of a lateraldrive ultrasonic metal welding device. The two basic types of joints being used for the ultrasonic welding of thermoplastics are the energy director ed joint and the shear joint. The present chapter is devoted chiefly to the effects that are observed in the bonding zone during ultrasonic welding. If at all possible, leave plenty of time for the part to cool after molding before welding. Extensive practical on tky welds shall be provided. Bending stress is eliminated by positioning the line of force directly over the welding surface. The weld formation is caused by the applica tion of external pressure and ultrasonic vibrations. Practical ultrasonic testing importance of weld profile. It is commonly used for plastics and metals, and especially for joining dissimilar materials.
Ultrasonic assembly process in ultrasonic welding, high frequency sound energy is used to bring the joining surfaces of two thermoplastic parts to a molten state where they can be permanently welded together. It is believed that the flattest possible testing angle should be used. Mar 01, 2008 proper ultrasonic welding setup can be drastically different when welding cold parts as opposed to welding hot parts. Ultrasonic metal welding developed during the 1950s through the 1990s as the electronics used in the equipment became. This bonding method permits the joining of thintothin or thintothick materials, including dissimilar metal joints. Currently he is a phd candidate in civil engineering specializing in structural engineering. Assembly metal welding the economics of ultrasonics u. Specification for standardized ultrasonic welding test.
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