Application of ultrasonic vibrations in welding and metal processing: A status review

Kumar, Sachin; Chen, Wu; Padhy, G.K.; Ding, Wei

doi:10.1016/j.jmapro.2017.02.027

Cited by 234 publications

(66 citation statements)

References 203 publications

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“…An experimental comparison of ultrasonic vibrationassisted drilling with an inductive sensor confirms the simulation results (Li et al, 2015). A specific solution is to use an additional passive piezoelectric disc integrated into the transducer (Yokozawa et al, 2017), as shown in Fig.…”

Section: Introductionsupporting

confidence: 77%

Close-to-process strain measurement in ultrasonic vibration-assisted turning

Kimme

Hafez

Titsch

et al. 2019

J. Sens. Sens. Syst.

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Abstract. The application of ultrasonic vibration assistance in machining offers many benefits over conventional machining. In some machining processes, like the generation of geometrically defined microstructures by cutting, the interaction of the system components and the machining process can be particularly crucial with respect to the production result. Monitoring of ultrasonic vibration-assisted machining in terms of the in-process measurement of frequency and amplitude is currently realized by measurement inside the actuator; thus, measurement is presently undertaken relatively far away from the cutting process. In this paper an in-process measurement set-up based on strain gauges positioned close to the cutting edges is presented. It is used to investigate the induced vibration in the ultrasonic horn. Experiments on machine samples with and without ultrasonic vibration assistance are performed using the in-process measurement set-up described. The results of the strain gauges are analysed in comparison to internal feedback signal and surface measurements. The experiments show the high sensitivity of the measurement set-up presented and a huge gain of information compared with the conventional measurement approach. This enables improved controllability of the excited mode shapes as well as in-process adjustment of the ultrasonic vibration frequency and amplitude for the manufacturing of defined microstructures.

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Section: Introductionsupporting

confidence: 77%

Close-to-process strain measurement in ultrasonic vibration-assisted turning

Kimme

Hafez

Titsch

et al. 2019

J. Sens. Sens. Syst.

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“…A comprehensive understanding on formation of joint in ultrasonic metal welding due to heat developed at the interface is still in dispute [10,11,12]. Based on literature survey, research pertaining to correlation of temperature generated at the interface during ultrasonic welding of electrical contacts with strength of the welded joints seems to be not reported.…”

Section: Introductionmentioning

confidence: 99%

Effect of Temperature Distribution in Ultrasonically Welded Joints of Copper Wire and Sheet Used for Electrical Contacts

2018

Materials

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The temperature distribution occurring at the interface while joining a simple electrical contact comprising of a copper wire and a copper sheet using ultrasonic metal welding was analyzed using finite element method. Heat flux due to plastic deformation and friction was calculated and provided as input load for simulation of temperature distribution. The results of temperature obtained from simulation are found to be in good agreement with the results of temperature from experiments measured using thermocouple. Special focus was given to how the heat generated at the wire–sheet interface affect the strength of the joint in tension. With the knowledge of heat generated at the interface while welding, it is possible to control the strength of the joint and produce defect free joints. Based on the results from finite element analysis and experiments, it is observed that the influence of heat developed due to friction and plastic deformation of metallic specimens has a significant effect on the progress of welding and strength of the joint.

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“…The coatings on the cermet prepared by the Chemical Vapor Deposition (CVD) technique exhibits excellent wear resistance, superior hardness, and excellent adhesion strength [109]. The ultrasonic vibrations assisted processes can improve the mechanical properties, and result in better material mixing and enhanced turbulence, which lead to the remarkable and globalized applications in the welding and joining of dissimilar metals [110].…”

Section: Othersmentioning

confidence: 99%

Dissimilar Welding and Joining of Cemented Carbides

Wang

Chen

et al. 2019

Metals

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Cemented carbides have been widely used in aerospace, biomedical/wearable sensor, automobile, microelectronic, and other manufacturing industries owing to their superior physical and chemical properties at elevated temperatures. These superior properties, however, make it difficult to process these materials using conventional manufacturing methods. In this article, an overview of the welding and joining processes of cemented carbide and steel is given, followed by a few examples of welding processes. Cemented carbides can be successfully joined by sinter-bonding, brazing and soldering, laser beam welding, tungsten inert gas (TIG) welding, diffusion welding, friction welding, electron-beam welding, and chemical vapor deposition. An overview of the benefits and drawbacks of brazing and soldering of cemented carbide and steel is presented, including reports on joint design, processes, and selection of brazing filler metals. The laser welding of cemented carbide and steel is addressed and reviewed, including reports on gap bridging ability, the inclusion/absence of filler metals, interlayers, and laser/TIG hybrid welding. Finally, a section is devoted to explaining the main issues remaining in the welding and joining of cemented carbide, corresponding solutions, and future work required.

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Application of ultrasonic vibrations in welding and metal processing: A status review

Cited by 234 publications

References 203 publications

Close-to-process strain measurement in ultrasonic vibration-assisted turning

Close-to-process strain measurement in ultrasonic vibration-assisted turning

Effect of Temperature Distribution in Ultrasonically Welded Joints of Copper Wire and Sheet Used for Electrical Contacts

Dissimilar Welding and Joining of Cemented Carbides

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