Ultrasonic Welding for Aerospace and automotive industries:
For automobiles, ultrasonic welding tends to be used to assemble large plastic and electrical components such as instrument panels, door panels, lamps, air ducts, steering wheels, upholstery and engine components.As plastics have continued to replace other materials in the design and manufacture of automobiles, the assembly and joining of plastic components has increasingly become a critical issue. Some of the advantages for ultrasonic welding are low cycle times, automation, low capital costs, and flexibility. Also, ultrasonic welding does not damage surface finish, which is a crucial consideration for many car manufacturers, because the high-frequency vibrations prevent marks from being generated.
Ultrasonic welding is generally utilized in the aerospace industry when joining thin sheet gauge metals and other lightweight materials. Aluminum is a difficult metal to weld using traditional techniques because of its high thermal conductivity. However, it is one of the easier materials to weld using ultrasonic welding because it is a softer metal and thus a solid-state weld is simple to achieve. Since aluminum is so widely used in the aerospace industry, it follows that ultrasonic welding is an important manufacturing process. Also, with the advent of new composite materials, ultrasonic welding is becoming even more prevalent. It has been used in the bonding of the popular composite material carbon fiber. Numerous studies have been done to find the optimum parameters that will produce quality welds for this material.