Joint design is a critical part of plastics welding, whether close or distant welding procedures are being performed. The ultrasound is then applied to the assembly for a fixed duration of time, typically between 0. It is believed that the flattest possible testing angle should be used. Specification for standardized ultrasonic welding test. In this chpater we present original materials obtained as a result of our. Potential pitfalls in ultrasonic plastic welding 201403. Manual ultrasonic inspection of thin metal welds 1. They know that ultrasonic welding is a fast,dependable way of joining wire to wire and wires to terminals. On optimization of some parameters in ultrasonic metal. For reference purposes the basic ultrasonic weld testing scheme is described in.
The book includes chapters on the following welding processes. Ultrasonic welding has many advantages over traditional methods. Welding and fabrication inspection contact ultrasonics. Ultrasonic testing ut uses high frequency sound waves. Some examples are vibration analysis, oil analysis, endoscope and thermography for drive train. This joining process is utilized in spottype weld ing, ring welding, line welding, and continuousseam welding ref. A new, more cost effective welding method was introduced in the 1940s. The objective of using two welding processes was to determine the influence of the microstructure on the inspection technology. The nondestructive ultrasonic weld spot inspection saves time and money and can be integrated into the production line for critical or hardtoreach points. The components to be welded are assembled in the tooling fixture before the welding horn descends and makes contact. The technique, ultrasonic welding, used highfrequency sound waves and pressure to bond metals together and required. Trinity ndt procedure for ultrasonic examination page 5 of 8 6. The primary advantages and disadvantages when compared to other ndt methods are. Ultrasonic welding of lithiumion batteries by seungjae lee a dissertation submitted in partial fulfillment of the requirements for the degree of doctor of philosophy mechanical.
If surface irregularities on the weld bead interfere with the ultrasonic test or cause. This specification, dealing with ultrasonic welding, was developed by the american welding society aws g1. Download ultrasonics pdf files on marine safety, cargo bulletins, hatch cover testing, maintenance, ultrasonic testing, iacs rec 14 and 15. Stanley inspection utilizes the pipewizard phased array pa systemcombined with a global team of certified operatorsto provide our customers with todays most comprehensive automated ultrasonic testing aut girth weld inspection services. May 31, 2017 ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. This ultrasonic welder consumes minimal energy, produces no arcs. The ultrasonic weld mechanism state of the technology. It starts with a simple model rod, covering the sound field, energy conversion and energy transmission.
Analysis of bonding strength of ultrasonic welding process. Ultrasonic welding component design and weld parameters. Pdf a guideline of ultrasonic inspection on butt welded plates. Welding and inspection sac joint venture a partnership of structural engineers association of california seaoc applied technology council atc california universities for research in earthquake engineering curee prepared for the sac joint venture partnership by matt johnson edison welding institute project oversight committee. The ultrasonic testing of welds is a much discussed but little used inspection technique, which, in theory, offers significant advantages to both customer and fabri cator. Phased array technology for weld inspection is becoming mature, with a draft standard for weld inspection bs en 5886, and this standard and technique were also adopted. Test samples the test samples specified consisted of plates 3, 4 and 5mm thick in ferritic and stainless steel, each containing 4 flaws. Process and quality characterization for ultrasonic welding of lithiumion batteries by seungjae lee a dissertation submitted in partial fulfillment of the requirements for the degree of doctor of philosophy mechanical engineering in the university of michigan 20 doctoral committee. Ultrasonic welding does have its limitations, though. Ultrasonic metal welding developed during the 1950s through the 1990s as the electronics used in the equipment became. The vibrations, produced by a welding sonotrode or horn, as it is generally known, are used to soften or melt the thermoplastic material at the joint line. Because of these advances, the process has been developed into a. On optimization of some parameters in ultrasonic metal welding. In this first article, gordon smith and uwe aschemeier offer a technicians guide to ultrasonic weld.
Physics of the ultrasonic welding process springerlink. Techbrief development of phasedarray ultrasonic testing. There is ultrasonic welding metal style, ultrasonic welding plastic style, ultrasonic nondestructive examination, and inspection of ultrasonic welds. Many factors have to be considered before a test can be. The welding horn is the element of the welding stack that supplies energy to the component being welded. Hybrid laser arc welding hlaw is a technology that promises to increase the efficiency of welded fabrication. Ultrasonic welding can join dissimilar metals in a split second, ultrasonic welding eases problematic. Close or near field welding is when the vibrating sonotrode is applied. Ultrasonic weld inspection is a complex process that requires qualified inspectors.
Nondestructive material testing with ultrasonicsis more than 40 years old. The stability of the welding process is increased and the effect of the human factor is reduced with rising automation. The range of automation covered ranges from simple mechanical aids to manual inspections through to sophisticated fully mechanised inspections under computer control. V22a, 6th main, 2nd stage, peenya industrial estate, bangalore560058, india. It offers many advantages, including process reliability and repeatability, lower energy usage than other joining techniques, material savings because there is no need for consumables, such as glue or mechanical fasteners, and labor savings. We the above signed, certify the statements in this record are correct and the welds were prepared and tested in accordance with. Ultrasonic metal welding ultrasonic metal welding is a technique suitable for joining both similar and dis similar metal work pieces 1. Also explore the seminar topics paper on ultrasonic metal welding with abstract or. This is a major advancement over an inspection only system. Explore ultrasonic metal welding with free download of seminar report and ppt in pdf and doc format. This authoritative resource brings together 600 pages of comprehensive information on solidstate and other welding and cutting processes. Resistance spot welding is the most important joining process in the mass production of car bodies. Ultrasonic test inspection free ndt sample procedures. The control of parameters can be ensured by suitable design of the welding device and corresponding control software.
Telsonic ultrasonic welding machines are suitable for all situations and production lines and provide a quick, easy and efficient installation. The control of parameters can be ensured by suitable design of the welding device and. Bethlehem steel corporation has been using this inspection technique as a pro duction tool for the last five years. Create a true solid state metallurgical bond with the lowest possible voltage drop with the wire splicer from sonobond ultrasonics. Pdf this paper explained the procedure to carry out the ultrasonic inspection for single and doublev butt welded plates in detail by including.
Pdf inspection by ultrasonic tomography ut leading trend in. In ultrasonic testing, the inspector must make a decision about the frequency of the. Welding machines are available both as compact units and as ultrasonic kits. Nondestructive testing ndt methods shall be selected in accordance with en 12062 by personnel qualified according to level 3 as defined in en 473. Telsonic ultrasonic welding machines are suitable for all situations and.
When this inspection system is integrated into the weld control unit, and measurements are allowed to influence control parameters during the welding process, the inspection system becomes a full. This ultrasonic welder consumes minimal energy, produces no arcs, sparks or fumes, and does not melt the wires. Ultrasonic welding, for thermoplastic injection moulded components, is a process that uses mechanical vibrations above the audible range. When this inspection system is integrated into the weld control unit, and measurements are allowed to influence control parameters during the welding process, the inspection system becomes a full quality assurance system. Ultrasonic welding is fast, requires no consumables, and can be applied to a wide variety of applications. Radiographic and ultrasonic weld inspection are the two most common methods of nondestructive testing ndt used to detect discontinuities within the internal structure of welds. Design of the welding horn is critical to successful welding. This study discusses the type of welding used in the industry, mainly involving the pipeline welds. Pdf real time nondestructive testing methods of welding.
The objective of using two welding processes was to determine the influence of the. The spotwelds are subject to a very high quality standard. Since i am not sure exactly which you mean, i am going to provide a brief description of ea. The psq 6000 system, from bosch rexroth, does this.
Bs en iso 17640 contains standard ultrasonic inspection techniques for ferritic steel welds. One method of inspection is to subject the material or weld to destructive tests, which would provide information about the performance of that test object. Also explore the seminar topics paper on ultrasonic metal welding with abstract or synopsis, documentation on advantages and disadvantages, base paper presentation slides for ieee final year mechanical engineering me or production automobile students for the year 2019 2020. A whole range of welding parameters has an important effect on quality of the resulting welded joint. Inprocess ultrasonic resistance weld inspection 200510017. Ultrasonic imaging with other advanced ultrasonic weld inspection techniques, proceedings of the 18th world conference on nondestructive testing, durban, 1620 april 2012. In this paper these two techniques are compared under the aspect of manual weld testing. The ultrasonic testing of welds is a much discussed but little used inspection technique, which, in theory, offers significant advantages to both customer. Custom multiple transducer heads have been used to. Analysis of bonding strength of ultrasonic welding process vijay singh pal, pavan agrawal abstract. The integrity of these connections during manufacturing as well as during the operation of mechanical equipment is of critical importance for the safety of the installation. I just assume that everybody who produces something will do so to the best of his or her ability. The search unit shall be manipulated so that the ultrasonic energy passes through the required. Guidebook for the fabrication of nondestructive testing.
Inspections performed according to international standards asme, en etc. Ultrasonic inspection service within the wind energy sector, several inspection techniques are known. Patented in 1960, ultrasonic welding for metals, has received significant research and there have been advances in the technology. After visually inspection cut materials have been then. Welding engineering program uia 2002, new york, ny results power and vibration amplitudes 0 500 1500 2000 2500 3000 0 0. Part of themechanical engineering commons, and themetallurgy commons. In ultrasonic welding, high frequency vibrations are combined with pressure to join two materials together quickly and securely. By incorporating automation, and integrating an automated inspection system, hlaw. Ultrasonic welding technology was invented and patented in the early 1930s and was originally used for the solidstate welding of metals 41. Ultrasonic weld inspections are typically performed using straight beam transducer in. Inspection of complex geometry welds with profile analysis of the weld using a pc. For spottype welding, the var iables under control of the welding machine operator are tip radius, nor mal load, electric power input to the transducer and weld time.
This process gives no indication of successful welding. First, the depths of the welds are less than a millimeter, so the process works best on thin materials like plastics, wires or thin sheets of metal. Weld quality assurance is the use of technological methods and actions to test or assure the quality of welds, and secondarily to confirm the presence, location and coverage of welds. After welding, the surface of the base metal where the probe is to be manipulated should be cleaned of weld splatter.
Ultrasonic inspection of a 9% ni steel joint welded with nibased. Mar 31, 2014 6 welding horn the welding horn is the element of the welding stack that supplies energy to the component being welded. The basic reason for this choice is the fact that typical production defects tend to be perpendicular to the plate surface or are astype a approach 38 typec approach o i. The obvious advantage of both these methods of testing is their ability to help establish the weld s internal integrity without destroying the welded component. The following is the first of a fourpart series that will take us back to the basics of weld inspection. This volume is devoted to information on resistance welding, solid state processes, and other joining and cutting methods. But how can we be sure about the actual quality of work our employees or we have done. Ring welding a circular tip used on a spot welder may be used to form a ring weld.
Welding and inspection sac joint venture a partnership of structural engineers association of california seaoc applied technology council atc california universities for research in. Generally ultrasonic testing or radiographic testing applies to butt welds and penetrant testing. This paper describes a series of experiments of conventional ultrasonic and phased array testing on thin butt welded sections with simulated flaws using the. Guidelines for automated ultrasonic inspection austenitic welds. For one, welding occurs at low temperatures relative to other methods. The latter are purposedesigned for incorporation in special machines, pro duction lines and multiplehead plants. The welding time is defined as the duration of ultrasonic and can be both a constant parameter and a variable. The flattest angle we consider practical for weld inspection is 75 deg. Microelectronic welding fine wire bonding represents the earliest widely used application for ultrasonic metal welding and still accounts for a large volume of industrial. Ultrasonic metal welding seminar report, ppt, pdf for. Nuregcr7159, reliability of ultrasonic inservice inspection of. Ultrasonic testing of a manual thick austenitic weldfeeedback. If the weld is not ground flushed the probe shall be controlled such that it faces nearly parallel to the weld body.
Immersion inspection is offered at a few of our fullservice ndt laboratories. Ultrasonic welding systems are very flexible and versatilely applicable and usually with little effort set up for different tasks. It is commonly used for plastics and metals, and especially for joining dissimilar materials. One solution for quality control is to carry out ultrasonic inspection for the. A brief overview of the two welding processes used to fabricate the specimens is described in the next section.
The inspection of welding and fabrication is needed to confirm that all welding procedures and standards are met, as well as, to ensure the welder is able to produce a weld free of defect. Pdf on mar 1, 2012, frank balle and others published ultrasonic welding find, read and cite all the research you need on researchgate. Pdf laser ultrasonic inspection of welds used in shipbuilding. The techniques in general include scans with different angles from. Ultrasonic welding component design and weld parameters twi. The technique, ultrasonic welding, used highfrequency sound waves and pressure to bond metals together and required less energy than conventional welding. This work aimed to optimize the phased array ultrasonic inspection of the thickwalled. Ultrasonic inspection report an ndt inspection test report, useful for documenting observations of ultrasonic inspections format no. Astm e 562 practice for determining volume fraction by systematic manual point. The weld formation is caused by the applica tion of external pressure and ultrasonic vibrations. An essential advantage of the digital ultrasonic testing devices for spot weld testing is the complete documentation capability as well as the userfriendly screen surface adapted to the.
Test method general the procedures given apply to the contact ultrasonic inspection of butt welds. Ultrasonic welding is an industrial technique whereby highfrequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solidstate weld. General the procedures given apply to the contact ultrasonic inspection of butt welds. The document gives guidance to managers and ndt engineers on the general types of automated ultrasonic ndt equipment and procedures currently in use for weld inspection. Line welding line welding is a variation of spot welding in which the weld geometry is elongated by using a linear sonotrode tip andor anvil. The ultrasonic inspection of thickwalled welded joint with. Such a classical field is the manual inspection of welds, which is applied worldwide in all industries and. If the weld fails inspection due to under welding e. The present chapter is devoted chiefly to the effects that are observed in the bonding zone during ultrasonic welding.
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