An ultrasonic systems and methods for sealing complex interfaces or for metal forming. Complex interfaces, such as a Gable top, have multiple and a variety of layers across the interface, or an oval or round spout having a complex geometry. An example system includes two ultrasonic horns arranged opposite a gap between which the interface is provided. The frequency and phase of the ultrasonic energy are synchronized as the energy is applied simultaneously while the interface is pressed between a jaw and the energy is applied to both sides of the interface. Another example system includes two ultrasonic transducers synchronized in frequency and phase and used to vibrate a horn mechanically to facilitate a sealing or welding interface or to assist in a metal-forming process.

A mechanical vibration machining apparatus or the like is suitable for forming a stable machined surface. A mechanical vibration machining apparatus performs machining of a machining target using a horn. A control unit instructs the horn to perform a mechanical vibration operation and a rotational driving operation. The control unit controls the mechanical vibration and/or the rotational driving in a periodic manner. For example, the control unit supports intermittent alternating control. That is to say, when one from among the mechanical vibration and the rotational driving is provided, the other is suspended. Such periodic control allows the stress that occurs due to the applied force to be dispersed, thereby allowing a stable machined surface to be formed.

A method of forming a cooling structure for a heat-dissipating surface includes arranging a heat spreader layer adjacent the heat-dissipating surface, bonding a coldplate directly to the heat spreader layer opposite the heat-dissipating surface, and forming an intermetallic bond between the heat spreader layer and the coldplate. The coldplate is bonded to the heat spreader layer using ultrasonic additive manufacturing.

A bonding tool that executes an ultrasonic vibration processing of applying ultrasonic vibration to an application portion on a lead wire from a direct contact tip portion and a pair of press mechanisms having a pair of press rollers capable of performing a rotational operation. The pair of press mechanisms executes a press processing of pressing both sides of the application portion on the lead wire by the pair of press rollers at a time of execution of the ultrasonic vibration processing by the bonding tool and a movement processing of executing a rotational operation performed by the pair of press rollers to move the pair of press rollers on the lead wire while pressing the lead wire at a time of non-execution of the ultrasonic vibration processing.

A bonding tool as the tool for ultrasonic bonding includes a plurality of protrusion portions in a protrusion region at a contact tip portion. The plurality of protrusion portions are equally spaced at a longitudinal direction interval in an X direction as the longitudinal direction of the protrusion region, and an X direction outermost protrusion portion positioned outermost in the X direction is disposed separately from a side edge of the protrusion region in the X direction by a longitudinal direction side edge distance. The plurality of protrusion portions are disposed so that a first disposition condition {0.349EX (the longitudinal direction side edge distance/DX (the longitudinal direction interval)0.510} is satisfied.

A method of making an annular component includes forming sheet feedstock into an annular shape disposed about a central axis; and bonding one portion of the feedstock to another portion of the feedstock using ultrasonic welding, so as to fix the annular shape.

An ultrasonic additive manufacturing system may include a base structure, a sonotrode configured to rotate about an axis of rotation, and one or more transducers configured to vibrate the sonotrode. The sonotrode may include a welding surface extending along a circumference of the sonotrode, and the welding surface may have a contoured profile. At least one of the sonotrode and the base structure may be configured to translate relative to the other of the sonotrode and the base structure.

A metal foil bonding device (50) for bonding pieces of metal foil (2) on the successively conveyed sheet-shaped electrodes (1) on the conveyor plates (20) is provided. When it is detected that there is an abnormality in a piece of metal foil (2) to be bonded to the sheet-shaped electrode (1) on the conveyor plate (20) next conveyed to the metal foil bonding device (50), the conveyor plate (20) next conveyed to the metal foil bonding device (50) is temporarily stopped right before the metal foil bonding device (50).

A manifold structure has at least one flow passage and a center manifold section that has at least one machined cavity. The manifold structure includes a plurality of ultrasonically additively manufactured (UAM) finstock layers arranged in the flow passage. After the finstock is formed by UAM, the finstock is permanently joined to the center manifold section via a brazing or welding process. Using UAM and a permanent joining process enables joining of the UAM finstock having enhanced thermal features to a vacuum brazement structure. UAM enables the finstock to be formed of dissimilar metal materials or multi-material laminate materials. UAM also enables bond joints of the finstock to be arranged at angles greater than ten degrees relative to a horizontal axis by using the same aluminum material in the UAM process and in the vacuum brazing process.

An ultrasonic processing method and an ultrasonic processing device may include a controlling/regulating module, preferably a digital controlling/regulating module, which is integrated into a signal processing of the ultrasonic generator so that a plurality of generator data with respect to the ultrasonic generator are processible in the ultrasonic generator. At this, a power actual value P.sub.ist is compared with a power reference value P.sub.soll of the ultrasonic generator via a gap regulator in the controlling/regulating module to specify a position reference value POS.sub.soll of the sonotrode relative to the roll for adjustment of the power reference value P.sub.soll of the ultrasonic generator, and/or a power actual value P.sub.ist is compared with a power reference value P.sub.soll of the ultrasonic generator via an amplitude regulator in the controlling/regulating module to specify an amplitude reference value A.sub.soll to the ultrasonic generator for adjustment of the power reference value P.sub.soll.