Evolution, Technology, and Efficiency of Ultrasonic Welding in Minimizing Material Dislocations

This study explores the creation and efficiency of friction welding using ultrasound, pointing out that there is minimal material dislocation. Chronologically, based on the piezoelectric effect discovered by Pierre and Jacques Curie in 1881, it converts electrical energy into mechanical vibrations, which cause frictional heat to join materials, typically metals and polymers. Key aspects to be discussed are working principles and equipment components, such as the transducer, booster, and welding horn, in addition to some discussion on comparisons of several ultrasonic welding processes using different metals and polymers. Besides that, various difficulties encountered in welding hard metals and dissimilar materials with brittle intermetallic compounds are also discussed. Among the innovative processes, some are ultrasonic extrusion weld riveting and two-vibration-system welding, both indicating high joint strength for applications related to automotive and aerospace industries. It also explains the document from changes in microstructure due to the ultrasonic welding process: dislocation, creep, softening, and hardening reduce the density of dislocations, thus increasing the strength of the materials.