Final Thesis

Simulating the sound from an Ultrasonic Metal Welding process for quality control

Key Info

Basic Information

Research Area:
Numerical Acoustics,
Type of Thesis:


Ultrasonic Metal Welding (USMW) is particularly suitable for connecting electrotechnical components. The concept is simple: two metal plates are pressed and rubbed against each other at 20 kHz. Due to friction, the plates are welded together. However, the quality of the weld fluctuates between each iteration. During experiments, vibrations of different parts of the welding machine are measured using laser vibrometers, and the airborne sound is measured using a microphone, up to 100 kHz. After initial experiments and simulations, it has become clear that the whole issue is very complex, and placement of the microphone is primordial to get useful data. The goal of this project is to simulate the sound field generated by the welding machine during welding. As welding progresses, the connection between different parts of the welding machine changes, and causes a change in the sound field generated. In this project, we will mostly deal with simulations (FEM, BEM, modal analysis, time-based or frequency-based). The different welding stages will be modeled as different connections and the sound field simulated each time, and the contribution of each of the different parts of the welding machine will be identified