ultrasonic welding presented by: ryan alexander chris baker jon stempka
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Ultrasonic Welding
Presented by: Presented by: Ryan AlexanderRyan Alexander
Chris BakerChris BakerJon StempkaJon Stempka
Purpose Ultrasonic device Ultrasonic device
and componentsand components Basic operationBasic operation ApplicationsApplications Advantages and Advantages and
disadvantagesdisadvantages Types of materialTypes of material Other welding Other welding
TechniquesTechniques
Types of Welds Friction weldFriction weld
Cold press weldCold press weld
Ultrasonic weldUltrasonic weld
Use of binder Use of binder materialmaterial
Hot Gas Welding
Less commonLess common
Uses hot gas to create localized meltUses hot gas to create localized melt
Binder material addedBinder material added
Advantages Simple equipmentSimple equipment
Simple OperationSimple Operation
Low CostLow Cost
Disadvantages Limited MaterialsLimited Materials
Limited part geometry Limited part geometry (sheet joining)(sheet joining)
Lower strengthLower strength
Ultrasonic welding of plastic VibrationsVibrations
Local Local PlastificationPlastification
Melting points Melting points must be equalmust be equal
Welding equipment Ultrasonic generatorUltrasonic generator
Ultrasonic welding deviceUltrasonic welding device
Ultrasonic transducer systemUltrasonic transducer system
Anvil and fixturesAnvil and fixtures
Ultrasonic generator 20 KHZ20 KHZ
35 KHZ35 KHZ
40 KHZ40 KHZ
Required holding and Required holding and welding timewelding time
Ultrasonic welding device 1. Sonotrode1. Sonotrode 2. High-tensile 2. High-tensile
threaded pinthreaded pin 3. Height adjustment3. Height adjustment 4. Converter4. Converter 5. Oscillating disk5. Oscillating disk 6. Booster6. Booster
Ultrasonic transducer system ConverterConverter
BoosterBooster
SonotrodeSonotrode
Anvil and Fixture
Typical example of sonotrode and Typical example of sonotrode and fixturefixture
Welding Parameters Welding EnergyWelding Energy
Mechanical StressMechanical Stress
Thermal StressThermal Stress
Welding Energy Contact pressureContact pressure
Welding timeWelding time
Trigger pointTrigger point
AmplitudeAmplitude
Welding toolsWelding tools
Ultrasonic Ultrasonic frequencyfrequency
Mechanical Stress AmplitudeAmplitude
Mechanical pressureMechanical pressure
Thermal stress Welding timeWelding time
AmplitudeAmplitude
Mechanical pressureMechanical pressure
Quality control Changeable Changeable
process-variable process-variable parametersparameters
Similar Similar characteristicscharacteristics
Parameter controlParameter control
Changeable process-variable parameters Weld timeWeld time
Weld energyWeld energy
Mechanical compression of the Mechanical compression of the parts to be weldedparts to be welded
Mechanical Compression Wrongly positioned Wrongly positioned
partsparts Selection of wrong Selection of wrong
partsparts Strongly Strongly
contaminated partscontaminated parts Deficiencies in Deficiencies in
welding equipmentwelding equipment
Welded parts should have similar characteristics Chemical Chemical
MechanicalMechanical
ProcessProcess
Typical ultrasonic welded plastics PS to PSPS to PS Nylon to NylonNylon to Nylon PP to PPPP to PP Compatible plastics such asCompatible plastics such as ABS to PSABS to PS SAN to ABSSAN to ABS
Parameter control Tool dimensionTool dimension
Weld pressureWeld pressure
Trigger pointTrigger point
AmplitudeAmplitude
Advantages
Clean, reliable, consistent, and affordable Clean, reliable, consistent, and affordable processprocess
No pre-weld or post-weld operationsNo pre-weld or post-weld operations Low consumption of energyLow consumption of energy Rapid repeatable process (often less than 1 Rapid repeatable process (often less than 1
second)second) Long tool lifeLong tool life
Disadvantages Plastics must have similar Plastics must have similar
characteristicscharacteristics Tool design requiredTool design required Joints maybe weakened by Joints maybe weakened by
incomplete fusionincomplete fusion
Applications Automotive Automotive
ToysToys
AppliancesAppliances
MedicalMedical
Automotive The average new car The average new car
has over 100 has over 100 ultrasonic welded ultrasonic welded partsparts
Toys Typical examplesTypical examples
Plastic and steel Plastic and steel ultrasonic weldingultrasonic welding
Medical Must be a Must be a
precision weld to precision weld to obtain FDA obtain FDA approvalapproval
Used because it is Used because it is a clean processa clean process
Appliances Used in many Used in many
every day every day household itemshousehold items
Conclusion Can be used for many applicationsCan be used for many applications Clean, reliable, consistent, and Clean, reliable, consistent, and
affordable processaffordable process Can be used with metal as well as Can be used with metal as well as
plasticplastic Quality control can be used in this Quality control can be used in this
process process
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