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Oak Ridge National Laboratory
Ultrasonic Welding
Processing/Manufacturing
Oak Ridge National Laboratory has a unique capability for joining similar and/or dissimilar
materials called “ultrasonic welding” (UW). UW is a solid-state joining process, where highfrequency ultrasonic vibrations are locally applied to workpieces by a vibrating tool
“sonotrode,” held under pressure. Joining is made by frictional heat generated at the interface
between the parts or surfaces.
The machine can join different material combinations with various material thicknesses. An
ultrasonic transducer that converts electrical power to mechanical vibratory power is at 20 kHz.
The maximum powers of ORNL’s UW equipment are 2500 and 3500 watt.
ORNL’s unique UW capability affords low energy input with no additional filler metal required.
It offers fast welding time in a clean, highly automated process. Weld bonding (with UW plus
adhesive) for corrosion mitigation and increased strength also is available.
The equipment is available for various partnership arrangements with industry.
Dr. Zhili Feng, [email protected]; 865-576-3797
Force
Transducer
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Sonotrode
Vibration direction
Frictional heat
Anvil
References: 1. Lai, W., Pan, J., Feng, Z., Santella, M. et al., "Failure Mode and Fatigue Behavior of
Ultrasonic Spot Welds with Adhesive in Lap-Shear Specimens of Magnesium and Steel
Sheets," SAE Int. J. Mater. Manf. 6(2):279-285, 2013, doi:10.4271/2013-01-1020.
2. Pan, T., Feng, Z., Santella, M., and Chen, J., "Corrosion Behavior of Mixed-Metal Joint of
Magnesium to Mild Steel by Ultrasonic Spot Welding with and without Adhesives," SAE Int.
J. Mater. Manf. 6(2):271-278, 2013, doi:10.4271/2013-01-1017.
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068 LightMat Capability
December 2015