Evaluation of welding performance of 20 kHz and 40 kHz ultrasonic metal welding

In this study, ultrasonic horns are designed by using vibration equations, vibration modal analysis and harmonic response analysis in order to compare welding performance when ultrasonic welding is performed at resonance frequencies of 20 kHz and 40 kHz. For the weldability evaluation of the manufactured horn for 20 kHz and 40 kHz, welding strength between Ni specimens with a thickness of 0.1 mm using tensile test are compared and analyzed. The lengths of horns with resonance frequencies of 20kHz and 40kHz were calculated as 130mm and 68mm respectively. As a result of vibration modal analysis, the optimum longitudinal vibration modes of 19,584Hz and 39,794Hz are obtained in 10th mode, and the frequency response of the two horns are 19,600 Hz and 39,800 Hz respectively. As the welding conditions are changed to welding pressure 2 bar, 3 bar and 4 bar, vibration amplitude of horn 60%, 80% and 100%, tensile strengths of welded specimens are observed. The welding strength was smaller at 40 kHz than at 20 kHz even at the same amplitude. This is because diffusion action of Ni in the weld interface is facilitated at 20 kHz than at 40 kHz.