Digest Ultrasonic Welding I: Localized Heating and Fuse Bonding

TL;DR

This paper introduces a new understanding of ultrasonic welding as an inverse shear band formation process, highlighting localized heating's role in bonding and crack repair, with a mathematical analogy to electric current heating.

Contribution

It presents a novel insight into ultrasonic welding physics, linking it to shear band formation and providing a mathematical model of heat generation similar to electric current.

Findings

Ultrasonic welding involves localized heating that bonds materials.

Heat generation in ultrasonic welding is mathematically similar to electric current heating.

The process can repair internal cracks through localized plastic deformation.

Abstract

This paper reports a new insight on the principle of ultrasonic welding process. Physics of ultrasonic welding process is considered to be an inverse process of shear band formation. Both ultrasonic welding and shear band formation involve temperature rising due to localized plastic deformation. During shear band formation, heat will lead to damage of materials, e.g., initiation of cracks inside materials. But heat generated in ultrasonic welding process will bond two pieces or repair the cracks inside materials. Energy directors used in ultrasonic welding process act as a trigger of localized plastic deformation. Mathematically, We found out that heating generation during ultrasonic welding process is similar to heating generation by electric current.