Abstract: A forming die that includes a body, wherein the body of the forming die includes at least one opening created therein; at least one die segment, wherein the at least one die segment is adapted to be inserted into the at least one opening in the body of the forming die, and wherein the at least one die segment is further adapted to receive ultrasonic vibrations; and at least one geometric feature formed within the at least one die segment, wherein the at least one geometric feature affects the ultrasonic vibrations in a predetermined manner.

Abstract: An ultrasonic machining module that includes an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a machining tool and a vibration-isolating housing adapted to be both compatible with a machining system and to receive the ultrasonic transducer therein, wherein the housing further includes at least one modification for isolating all vibrations generated by the ultrasonic transducer when the device is in operation except axial vibrations transmitted to the machining tool, thereby preventing unwanted vibrations from traveling backward or upward into the machining system.

Abstract: An ultrasonic welding apparatus that includes a full-wave sonotrode that further includes a first horn, a first nodal region, a welding surface, a second nodal region, and a second horn; first and second bearing assemblies that support the sonotrode at the first and second nodal regions respectively, wherein each bearing assembly further includes a first bearing housing portion; a first low friction bearing disposed within the first bearing housing portion; a second bearing housing portion connected to the first bearing housing portion; and a second low friction bearing disposed within the second bearing housing portion; a first centering apparatus that exerts laterally-acting force on the horn of the full-wave sonotrode; and a second centering apparatus that exerts laterally-acting force on the second horn of the full-wave sonotrode.

Abstract: An ultrasonic machining module that includes an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a machining tool and a vibration-isolating housing adapted to be both compatible with a machining system and to receive the ultrasonic transducer therein, wherein the housing further includes at least one modification for isolating all vibrations generated by the ultrasonic transducer when the device is in operation except axial vibrations transmitted to the machining tool, thereby preventing unwanted vibrations from traveling backward or upward into the machining system.

Abstract: An aluminum tubular unit for long-term, leak-free storage of fluids is formed in which an aluminum cap is ultrasonically welded to an end of the aluminum tube. The ultrasonic weld is formed from a device capable of producing a torsional vibration pattern. The ultrasonic welding of the cap to the tube eliminates the use of seals and pins to seal the cap to the tube and further eliminates the need for having a hole in the cap to mechanically couple the respective end cap to the cylindrical tube. Furthermore, since ultrasonic welding does not generate significant heat, highly volatile and flammable fluids can be present within the tube when the caps are ultrasonically welded to the cylindrical body. In addition, one or more fins used may also be welded to the outside diameter of the cylindrical body using a related ultrasonic welding process.