Ultrasonic Metal Welding (USMW) is solid-state bonding process where two metal pieces are joined by the application of ultrasonic vibrations. This thesis focuses on the study of the sonotrode during a free run to understand the airborne sound field generated during the welding process.

Simulation data are generated using COMSOL Multiphysics to model the physics involved during USMW with different studies: solid mechanics time-dependent, pressure acoustics transient and pressure acoustics, boundary elements. Simulation results are presented using FEM and BEM methods, with different 2D and 3D geometry models and including the effect of surface reflexions.

Finally simulations and measurements are compared to find possible microphone positions for an acoustic monitoring method.

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