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
- Slides: 30