Ultrasonic welding machine to form the major joints, static pressure and temperature three factors weld zone is determined by the vibration of the shear force, the interaction between them, mutual restraint, and the thickness, surface condition and room temperature properties of the weldment related.
For wire ultrasonic welding machine process steps can be divided into the following steps:
First, the diffusion welding
Diffusion welding pressure is small, does not produce macroscopic plastic deformation of the workpiece after welding is no longer suitable for machining precision parts. Diffusion bonding with other thermal processing technology combine to form a combination of processes, such as heat loss - diffusion welding, powder sintering - superplastic forming and diffusion bonding - such as diffusion bonding. The combined process will not only greatly improve the productivity, but also can solve a single process can not solve the problem. Such as various titanium member supersonic aircraft is the application of superplastic forming - the diffusion properties of welded joints made of diffusion welding can be the same as the base material, particularly suitable for welding dissimilar metallic materials, graphite and ceramics and other non-metallic materials, dispersion strengthened high-temperature alloys, metal matrix composites and porous sintered materials. Diffusion bonding has been widely used reactor fuel elements, honeycomb structural panels, electrostatic accelerating tube, the manufacture of various blades, impellers, dies, filter tubes and electronic components and the like.
Diffusion welding ultrasonic welding machine is at a certain temperature and pressure will be planted material to be welded weld surface contact with each other, and the expansion of physical contact surfaces to be welded by microscopic plastic deformation or produce small quantities of liquid through the welding surface, so that the distance from the up (1 ~ 5) x10-8cm within (gravitation between atoms act like this, it is possible to form a metal key), and then by atomic diffusion constant for a long time with each other, the mutual penetration welding method to achieve a metallurgical bond . Obviously, those of ordinary harness welding, diffusion bonding using the cost is too high.
The weldment close contact, at a certain temperature and pressure for a period of time, so that the atomic interdiffusion between the contact surface of the welding method forming the coupling. The main factors affecting the diffusion welding process and the joint quality is temperature and pressure diffusion time and surface roughness. The higher soldering temperature, the faster the atomic diffusion welding material melting temperature is generally 0.5 to 0.8 times. According to the type of material and the joint quality requirements, diffusion welding in a vacuum, carried out under protective gas or solvent, in which the most widely used vacuum diffusion bonding. To speed up the welding process, reducing the surface roughness of the welding requirements or prevent unwanted tissue of joints, often add specific component of the mid sole material between the welding surfaces, having a thickness of about 0.01 mm.
Second, the high-frequency welding
High-frequency welding is a solid resistance heat energy. The use of high-frequency current welding resistance heat generated within the workpiece so that the workpiece surface is heated to melt the welding area or close to a plastic state, then applied (or not applied) forging force and achieve a combination of metals. So it is a solid phase resistance welding method. High-frequency welding, depending on how high-frequency current to generate heat in the workpiece can be divided into contact with a high-frequency induction welding and high frequency welding. Contact frequency welding, high frequency current through mechanical contact with the workpiece and the incoming workpiece. High frequency induction welding, the high-frequency current through an external coupling piece induction coil to generate the induced current in the workpiece. High-frequency welding is highly specialized welding method, according to the product is equipped with special equipment. High productivity, welding speeds of up to 30m / min. Mainly used for longitudinal seam or spiral seam welded pipe manufacturing. Obviously, for small harness, high-frequency welding is not applicable.
Third, cold welding
Ultrasonic welding machine work surface and mold metal debris may accumulate and must be periodically removed. If compressed air, compressed air can be used to blow off debris. If you want to completely remove debris, mold can be removed from the welding machine, the mold is open four modules, each module with a magnifying glass carefully to ensure that all modules surface trace of debris have been cleared. Be careful when Chaimo, are particularly vulnerable to the loss of small springs. Not clean the surface of the mold will cause the wiring in the mold when the line is easy to slip, so welding failure. Note that the working surface of the mold after maintenance will never allow any grease.
Due to cold welding without heating, no filler, a simple device; main welding process parameters determined by the size of the mold, it is easy to operate and automation, stable welding quality, high productivity, low cost; no solder joints will not cause corrosion ; welding joint temperature does not rise, the crystalline state of the material change, and is particularly suitable for thermal welding of dissimilar metals can not be achieved welding metallic materials and products. Cold welding electrical industry has become one of the aluminum industry in the field of welding and space is limited in several of the most important method of ultrasonic welding.