Table˙3. Loss measurements for various stainless steels Check mat composition from inspection sheets rather than matweb Check if hardness for Ti Send horns out for hardness tests (all HRC) Mats in my folders Fry solder horns - CPM9, FX Solidica - D2, M2, Temper2 FX (see hanging folder "20 kHz shear weld horn - steel"; f drop from heat treat in Joe Mocarski "Machining" manilla folder) Delphi metal welding horn - CPM10?, M2 Dukane, Abba - CPM10 Robert Foster (Sonic Tool) Bullen - stainless steel Alpha Precision - D2 (tried CPM but it was more lossy than D2) ? (cyl horn with lighthouse contour) - AlBeMet Steel mats used for horns - D2, CPM10v (http://www.bmsonics.com/index.html) CPM, tool steel (http://www.patsonics.com/ultrasonichorns.htm) D2, CPM (http://www.plasticsdecorating.com/stories/052013/assembly.shtml#.WfItg3ZulaR) - "Considerations in Frequency, Thermoplastic Type and Metal Type for Ultrasonic Horns" Gary Clodfelter is president of Plastics Assembly Technologies, Inc. (PATSONICS) "D2 steel is very prone to fatiguing at ultrasonic frequencies where high gain levels are required for the application. Fortunately, the app?lication where D2 tool steel most commonly is used for ultrasonic assembly is installing metal components into plastic parts, and this application does not require high amplitude. Since ultrasonic metal insertion is a high-wear application, D2 steel proves to be the material of choice for high-production insertion jobs." "For some high-wear applications where the plastic material is particularly abrasive to the horn face, CPM steel has been used. Although the CPM steel can run at an amplitude level exceeding aluminum, it also has a higher resistance to acoustical energy transfer than aluminum or titanium. Therefore, CPM is not acoustically as efficient as titanium or aluminum." CPM (Vieira, Frank (Branson) - US patent 20150007704A1 (2015-01-08), 'Ultrasonic Steel Horn for Tire Cutting and Method of Manufacturing'.pdf) M2 Branson Ultrasonics and Stapla Ultrasonics - for metal welding (Robert Foster (Sonic Tool) letter 3/1/2006) de Vries, Edgar - 'Mechanics and Mechanisms of Ultrasonic Metal Welding' (PhD dissertation, 2004) p. 10 - Figure 2.1 - Wedge-Reed & Lateral Drive Systems p. 91 M2 heat treated sonotrode & anvil (Sonobond) - unclear if "sonotrode" means just the tip or the entire reed AISI 1030 carbon steel Al-Sarraf - 'A Study of Ultrasonic Metal Welding' (thesis, 2013) - Glasgow U. "AISI 1030 carbon steel was selected as the horn material due to its high wear resistance, which is desirable for USMW [101]." (p. 52) Vickers hardness = 188 (p. 53) Ref. 101 -- A. Shoh, "Welding of Thermoplastics by Ultrasound," Ultrasonics, vol. 14, no. 5, pp. 209-217, 1976. Properties: p. 53 "In this study, a flat welding tip protrusion was designed as an integral horn tip to achieve the conditions of spot welding and to ensure sufficient energy is transferred to the welding zone. The welding tip was machined from the same horn material, AISI 1030 carbon steel, and hardened to 55-60 RC by quenching from 1100oC." (p. 54) Also discusses tip knurl. Fig 1-5 (p. 9) shows 2 metal welding configs - wedge-reed & lateral drive (used for this study - p. 11) "this study investigates the welding of thin metal specimens, which require high vibration amplitude with low applied force and this can best be obtained from the lateral-drive system." p. 19 - discusses various FEA analyses (Adachi[47], O'Shea[48], ...) p. 32 - "In addition, the wedge-reed system usually requires low amplitudes to allow high energy transferral to the welding zone. Therefore, low amplitude is recommended in wedge-reed systems due to the requirement of high force [29, 72]." p. 33 - "The lateral-drive system requires a low clamping force with high amplitude to produce the weld, whilst high force with low amplitude is recommended in a wedge-reed system [29]." p. 37 - "High-quality welding results in part from tooling with high hardness to avoid deformation and high toughness to prevent fractures [27 - M. Bloss, Ultrasonic Metal Welding: The Weldability of Stainless Steel, Titanium and Nickel-Based Super Alloys, PhD Thesis, University of Ohio, 2008.]." [28] - E. de Vries, Mechanics and Mechanisms of Ultrasonic Metal Welding, PhD Thesis, University of Ohio, 2004. Low carbon steel (unspecified) Nguyen__'Manufacturing_of_Ultrasonic_Horn_For_Bonding_Non-Woven_Materials' 304 SS http://www.hielscher.com/i4000_p.htm Uses stainless steel 1.4301 (304 SS) for sonochemistry probes. See http://www.brownmac.com/products/stainless-steel-plate/Stainless-Steel-304-and-304l.aspx 420 SS Bullen 02-033-01-00-0.dwg (20k 5" square) FerroTiC (FerroTitanit cermet) Emmer - 'Materials for Sonotrode Tools'.pdf - Compared to CPM 10V (gives heat treatment); also ASTM 5115 & 5117 Gives references - [1] Lucas, M., Petzing, J.N., Cardoni, A., Smith, L.J., "Design and characterisation of ultrasonic cutting tools", CIRP Annals - Manufacturing Technology, Vol. 50, 2001, pp. 149-152 --> can request through ResearchGate --> possibly same info as in Cardoni - "CHARACTERISING THE DYNAMIC RESPONSE OF ULTRASONIC CUTTING DEVICES" 2003 [2] Lucas M., MacBeath, A., McCulloch, E., Cardoni, A., A finite element model for ultrasonic cutting, Ultrasonics, Vol. 44, 2006, pp. e503?e5 ****** To do *********************** topic ss_loss_measurements Associated table Calibrate Young's modulus by FEA Do hardness checks Hudson (1942 PhD thesis) - "High damping capacity in steel is accompanied by low notch sensitivity, and vice versa." (p. 12) Bryson article - Thanks for publication. "Legal" version available from Researchgate.net? Buy used book. Fatigue Include Campbell graph (p. 245) For a large number of steels, there is a direct correlation between tensile strength and fatigue strength; higher-tensile-strength steels have higher endurance limits. The endurance limit is normally in the range of 0.35 to 0.60 of the tensile strength. This relationship holds up to a hardness of approximately 40 HRC (~1200 MPa, or 180 ksi tensile strength), and then the scatter becomes too great to be reliable (Fig. 14.5). This does not necessarily mean it is wise to use as high a strength steel as possible to maximize fatigue life because, as the tensile strength increases, the fracture toughness decreases and the environmental sensitivity increases. The endurance limit of high-strength steels is extremely sensitive to surface condition, residual-stress state, and the presence of inclusions that act as stress concentrations. Crucible (telecon John Shiesley, VP sales, 800-365-1180 x9135) 2017-11-15 Notch sensitivity - Use C-notch (V-notch not appropriate for these steels) Crucible - Benefits of cPM V series vs Rex series Give approx f drop from heat treatment See Crucible Rex pdfs -- change in L with heat treat. Joe Mocarski - f drop (due to E change or L change?) Thread failures Pictures Solidica J thds improved Asymmetric thd tap Helicoil inserts Wuchinich data - high power tests Allow clicking on bigger version (pdf) of Maropis 15k loss test graph. Graph Branson D2 Q vs ampl data Effect of temperature on modulus & Poisson - See "Symposium on Elastic Constants"\"The Influence of Temperature on the Elastic Constants of Some Commerical Steels" Measure hardness of my SS test horns to see if any correlation to loss =========================================================== SS composition from matweb.com - relevant to SS loss (Table˙3. Loss measurements for various stainless steels) =========================================================== 303 SS Component Elements Properties Metric Carbon, C <= 0.15 % Chromium, Cr 18 % Iron, Fe 69 % Manganese, Mn <= 2.0 % Molybdenum, Mo <= 0.60 % Nickel, Ni 9.0 % Phosphorous, P <= 0.20 % Silicon, Si <= 1.0 % Sulfur, S >= 0.15 % =========================================================== 316 SS Component Elements Properties Metric English Comments Carbon, C <= 0.070 % Chromium, Cr 16 - 18 % Iron, Fe 61.9 - 72 % Manganese, Mn <= 2.0 % Molybdenum, Mo 2.0 - 3.0 % Nickel, Ni 10 - 14 % Silicon, Si <= 1.0 % =========================================================== 416 SS Component Elements Properties Metric English Comments Carbon, C <= 0.15 % Chromium, Cr 13 % Iron, Fe 84 % Manganese, Mn <= 1.25 % Molybdenum, Mo <= 0.60 % Phosphorous, P <= 0.060 % Silicon, Si <= 1.0 % Sulfur, S >= 0.15 % =========================================================== 420 SS Component Elements Properties Metric English Comments Carbon, C 0.15 - 0.40 % Chromium, Cr 12 - 14 % Iron, Fe 81.6 - 87.9 % Manganese, Mn <= 1.0 % Other <= 2.0 % Silicon, Si <= 1.0 %