The Experimental Investigation and Optimization of the Effects of Ultrasonic Welding Parameters on Weld Quality

Abstract

Ultrasonic welding is a widely used industrial process for joining plastics and metals, especially dissimilar materials. In this process, the workpieces are held together under pressure and joined using high-frequency ultrasonic acoustic vibrations. Achieving the desired weld quality is crucial for the overall integrity of the final product. Therefore, investigating and optimizing the effects of ultrasonic welding parameters on weld quality is of significant importance. This study presents an experimental investigation aimed at understanding and optimizing the impact of various ultrasonic welding parameters on weld quality. An experimental study was conducted to analyze the effects of ultrasonic welding parameters such as amplitude, pressure, and time on weld quality. The Taguchi method was employed to minimize the number of experiments and determine the optimal combination of welding parameters that maximize the desired weld quality characteristics. The Taguchi experimental design method is a statistical approach that allows for the consideration of multiple factors simultaneously while achieving the most optimal result with fewer experiments. According to this method, a series of experiments were designed based on the L9 orthogonal array. The tensile test results of the samples obtained from the experiments were evaluated as the response variable to determine the weld quality. The results were statistically analyzed using Minitab software to identify the significant factors affecting weld quality and their interactions. The data revealed that the best weld strength was achieved at 4 bar pressure, 1 second processing time, and 90 Hz amplitude. Additionally, a correlation between the increase in these parameters and weld quality was established. In conclusion, this study demonstrated that the Taguchi method could be effectively applied to optimize ultrasonic welding parameters to achieve high-quality welds. The findings contribute to the advancement of ultrasonic welding technology, providing a basis for developing efficient and reliable welding processes for various applications and material combinations.