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Ultrasonic Horn Design and Weldability in Thin Ni Plates Welding

In this research, a new ultrasonic horn is designed and fabricated for welding thin Ni plates by vibration analysis. Two types of the horn tip are fabricated to evaluate the effect of horn’s tip on the weldability. Modal analysis, harmonic response analysis and FFT analysis are carried out for verifying the adequacy of the developed horn. To evaluate weldability of two types of horn tip, welding strength and the microstructure of the weld surface are experimentally investigated with various welding parameters such as pressure, time and vibration amplitude. Finally, the new horn with resonant frequency of 40 kHz is developed, and it is shown that welding strength and the microstructure of the weld surface are largely affected by horn’s tip shape.