A Review On Ultrasonic Welding Capability: Breakaway From Traditional Plastic Mohd Azam Musa 1, a * , Wan Ahmad Najmuddin Wan Saidin 1, b , Nazrul Idzham Kasim 1, c , Mohd Irman Ibrahim 1, d , Noraishah Mohamad Noor 1, e 1 International College of Automotive, DRB-Hicom Automotive Complex, Pekan, Pahang, Malaysia a azam@icam.edu.my, b najmuddin@icam.edu.my, c idzham@icam.edu.my, d irman@icam.edu.my, e noraishah@icam.edu.my Keywords: Ultrasonic, Multi metal, SMT, Textile, Joining material, Anvil. Abstract. The joint technology using ultrasonic welding is used to bond plastic material. Currently there are many researches to study the feasibility of using ultrasonic bonding to joint other materials. This paper reviewed the study on using ultrasonic bonding to joint multi metal, surface mount component, and textile material. The process configurations of each material are discussed and the results for each study are also presented. The multi metal materials bonding result shows that these materials bonded well to each other. The ultrasonic bonding strength for SMT components was as good as reflow oven and it was cosmetically accepted. The configuration of textile materials is investigated using vibrating ultrasonic horn and stationary anvil using high mechanical vibration and the result show it can be integrated ultrasonically. With advancement of computer control in ultrasonic welding, this technology can be used for any material in future to achieve world class manufacturing. Introduction Ultrasonic welding techniques have been used successfully for over 25 years in many industries using plastics. The process utilizes a thermoplastic resin's ability to form a welded joint by generating heat at the joint interface by mechanical vibratory energy. Once the resin becomes molten or plasticized at the joint it flows across the interface to form a homogeneous link of the two plastic parts [1]. This welding technique solves many manufacturing problems for industries concerning bonding and fastening of materials and related labor costs. It will provide a fast, controlled and repeatable method of achieving a permanent strong bond between two parts. Originally developed to weld plastics, ultrasonic welding has gained inroads into various welding applications including metal, surface mount assembly, printed circuit board, and even textile materials. Although this technology has a higher initial cost than resistance welding and other assembly techniques, its speed and flexibility provide for a good payback in a short period of time. Additional advantages, such as its capability to be linked with microprocessors and to be integrated into automated processes, make it even more attractive to manufacturers seeking a competitive edge and a "world class" manufacturing capability. Multi Metal Ultrasonic Bonding Process Configuration Multi metal ultrasonic bonding combines ultrasonic metal welding and layered manufacturing techniques to produce three-dimensional freeform objects. The process uses the power of high frequency ultrasonic vibration at low amplitudes to bond thin foils of materials to form solid objects. It combines normal and oscillating shear forces on mating foils; and the resulting friction forces between materials to fracture and displace surface oxides. The exposed atomically Applied Mechanics and Materials Vols. 789-790 (2015) pp 136-140 Submitted: 2015-05-15 © (2015) Trans Tech Publications, Switzerland Accepted: 2015-06-03 doi:10.4028/www.scientific.net/AMM.789-790.136 All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of Trans Tech Publications, www.ttp.net. (ID: 183.171.224.68-07/07/15,02:22:15)