Ultrasonic and Welding
Fusion welding is a welding process that relies on melting to join materials of similar compositions and melting points. The parent metal is also melted and joint, but this process requires no pressure.
Pressure welding is a cold welding and contact welding process. Joining takes place because pressure is introduced to the two parts to be welded, without need for fusion or heating at the interface.
Brazing and Soldering
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing solder into the joint, the solder having a lower melting point than the adjoining metal. The parent metal is not melted.
|Fusion Welding||Arc welding||Non-consumable electrodes||Non-gas shielded arc||Carbon arc welding (CAW)|
|Shield arc||Atomic hydrogen welding|
|Gas metal arc welding (MIG)|
|Consumable electrodes||Non-gas shielded arc||Metal arc welding|
|Submerged arc welding (SAW)|
|Shielded arc||Shielded metal arc welding (SMAW)|
|Gas metal arc welding (MIG)|
|Carbon-dioxide arc welding|
|Oxygen fuel gas welding||Heat welding|
|Electron beam welding (EBW)|
|Pressure Welding||Heat assisted||Crimping|
|Resistance welding||Overlap||Electric welding|
|Flash butt welding|
Advanced Welding Techniques
Advanced welding technologies mainly include the ultrasonic welding, high-frequency welding, laser welding and plasma welding, in which the energy comes in forms that differ from traditional bonding technologies.
About ultrasonic metal welding
Ultrasonic metal welding is a technologically advanced method of bonding non-ferrous metals, with advantages in precision and safety compared to traditional bonding technologies. Many industries demand precision welding for small and delicate parts, so ultrasonic metal welding is becoming widely accepted by industrial applications.
It is an environmentally friendly process as no heat is applied and no consumables, such as solder, are needed. A weld typically takes seconds or fractions of a second and the welder is easy to operate. The weld nugget has a superior conductivity and stability. Ultrasonic metal welding is a cost-saving choice for industrial users.
As an advanced bonding method, ultrasonic metal welding is a process in which the high-frequency mechanical vibrations scrub the workpieces against each other under pressure. The parent metal is not melted, and the welding point is a true metallurgical bond. The energy required for this process is less than 10% of that needed for arc welding.
Suitability of Materials for Ultrasonic Bonding
The most suitable materials for ultrasonic welding are copper, aluminum and nickel. The two parts to be welded can be either the same material or different materials. The more similar melting points the two materials have, and the lower the materials are in hardness and thickness, the easier the welding is. Now there has been a wide application in welding of metal foils to terminals.