Ultrasonic Welding Presented by Ryan Alexander Chris Baker

Ultrasonic Welding Presented by: Ryan Alexander Chris Baker Jon Stempka

Purpose n n n Ultrasonic device and components Basic operation Applications Advantages and disadvantages Types of material Other welding Techniques

Types of Welds n Friction weld n Cold press weld n Ultrasonic weld n Use of binder material

Hot Gas Welding n Less common n Uses hot gas to create localized melt n Binder material added

Advantages n Simple equipment n Simple Operation n Low Cost

Disadvantages n Limited Materials n Limited part geometry (sheet joining) n Lower strength

Ultrasonic welding of plastic n Vibrations n Local Plastification n Melting points must be equal

Welding equipment n Ultrasonic generator n Ultrasonic welding device n Ultrasonic transducer system n Anvil and fixtures

Ultrasonic generator n 20 KHZ n 35 KHZ n 40 KHZ n Required holding and welding time

Ultrasonic welding device n n n 1. Sonotrode 2. High-tensile threaded pin 3. Height adjustment 4. Converter 5. Oscillating disk 6. Booster

Ultrasonic transducer system n Converter n Booster n Sonotrode

Anvil and Fixture n Typical example of sonotrode and fixture

Welding Parameters n Welding Energy n Mechanical Stress n Thermal Stress

Welding Energy n Contact pressure n Amplitude n Welding time n Welding tools n Trigger point n Ultrasonic frequency

Mechanical Stress n Amplitude n Mechanical pressure

Thermal stress n Welding time n Amplitude n Mechanical pressure

Quality control n Changeable processvariable parameters n Similar characteristics n Parameter control

Changeable process-variable parameters n Weld time n Weld energy n Mechanical compression of the parts to be welded

Mechanical Compression n n Wrongly positioned parts Selection of wrong parts Strongly contaminated parts Deficiencies in welding equipment

Welded parts should have similar characteristics n Chemical n Mechanical n Process

Typical ultrasonic welded plastics PS to PS n Nylon to Nylon n PP to PP n Compatible plastics such as n ABS to PS n SAN to ABS n

Parameter control n Tool dimension n Weld pressure n Trigger point n Amplitude

Advantages Clean, reliable, consistent, and affordable process n No pre-weld or post-weld operations n Low consumption of energy n Rapid repeatable process (often less than 1 second) n Long tool life n

Disadvantages Plastics must have similar characteristics n Tool design required n Joints maybe weakened by incomplete fusion n

Applications n Automotive n Toys n Appliances n Medical

Automotive n The average new car has over 100 ultrasonic welded parts

Toys n Typical examples n Plastic and steel ultrasonic welding

Medical n n Must be a precision weld to obtain FDA approval Used because it is a clean process

Appliances n Used in many every day household items

Conclusion Can be used for many applications n Clean, reliable, consistent, and affordable process n Can be used with metal as well as plastic n Quality control can be used in this process n