高频调制电弧的声学特性及其细化焊缝组织的应用

以等离子体电弧作为声源,利用高频电流进行调制,激发电弧可以产生超声波。研究了高频调制电弧的激发特性和声场特征,发现调制电弧所发射超声波在激励频段内呈现平坦的幅频特性,激励电流是影响电弧超声强度的主要因素,声压幅值与电弧等离子体流力的变化量成正比,声场呈现轴向强两侧弱的特征。同时介绍了利用电弧激发超声波在改善焊缝组织性能方面的应用。  

超声纸杯焊接技术

本文介绍一种超声纸杯焊接设备及焊接工艺。  

The ultrasonic characteristics of high frequency modulated arc and its application in material processing

To solve the difficulty of introducing traditional ultrasonic transducers to welding molten pool, high frequency current is used to modulate plasma arc and ultrasonic wave is excited successfully. The characteristics of the excited ultrasonic field are studied. The results show that the amplitude-frequency response of the ultrasonic emission is flat. The modulating current is the main factor influencing the ultrasonic power and the sound pressure depends on the variation of arc plasma stream force. Experimental study of the welding structure indicates grain refinement by the ultrasonic emission of the modulated arc and the test results showed there should be an energy region for the arc ultrasonic to get best welding joints.  

A nonrational B-spline profiled horn with high displacement amplification for ultrasonic welding

A new horn with high displacement amplification for ultrasonic welding is developed. The profile of the horn is a nonrational B-spline curve with an open uniform knot vector. The ultrasonic actuation of the horn exploits the first longitudinal displacement mode of the horn. The horn is designed by an optimization scheme and finite element analyses. Performances of the proposed horn have been evaluated by experiments. The displacement amplification of the proposed horn is 41.4% and 8.6% higher than that of the traditional catenoidal horn and a Bézier-profile horn, respectively, with the same length and end surface diameters. The developed horn has a lower displacement amplification than the nonuniform rational B-spline profiled horn but a much smoother stress distribution. The developed horn, the catenoidal horn, and the Bézier horn are fabricated and used for ultrasonic welding of lap-shear specimens. The bonding strength of the joints welded by the open uniform nonrational B-spline (OUNBS) horn is the highest among the three horns for the various welding parameters considered. The locations of the failure mode and the distribution of the voids of the specimens are investigated to explain the reason of the high bonding strength achieved by the OUNBS horn.  

On the effect of flat energy directors thickness on heat generation during ultrasonic welding of thermoplastic composites

This paper presents a detailed experimental assessment of the effect of the thickness of flat energy directors (ED) on heat generation at the interface during ultrasonic welding. Power and displacement data showed clear differences caused by the change of thickness, related to heat concentration at the weld line during the process. The extent of the heat-affected zone was assessed by welding specimens without consolidation at different stages of the process. It was confirmed through optical microscopy that heat is generated at the interface and transferred to the bulk adherends earlier in the process for thinner ED. The analysis of their fracture surface under optimum welding conditions revealed signs of matrix degradation, leading to less consistent quality, likely due to faster heat generation rate in both the ED and the substrates, and incidentally, higher temperatures surrounding the energy director.  

Ultrasonic welding of CF/PPS composites with integrated triangular energy directors: melting,flow and weld strength development

This paper presents a fully experimental study on melting, flow and weld strength development during ultrasonic welding of CF/PPS composites with integrated triangular energy directors. The main goal of this research was assessing whether the heating time to achieve maximum weld strength could be significantly reduced as compared to ultrasonic welding with flat energy directors. The main conclusion is that, in the specific case under study, the triangular energy directors did heat up, melt and collapse approximately two times faster than the time it took for the flat energy directors to melt and significantly flow. However the heating time needed to achieve maximum weld strength for the integrated triangular energy directors did not differ drastically from that for flat energy directors. This was caused by the fact that a fully welded overlap was not directly achieved right after the collapsing of the triangular energy directors. Instead a solidified resin-rich interface was created which needed to be re-melted as a whole in order to achieve a fully welded overlap and hence maximum weld strength.