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