Ultrasonic welding is a type of solid state welding. It does not involve melting of the materials. Instead, it uses vibrations, which are actually ultrasonic sound waves, to connect objects. Pressure is applied to the materials until they become welded together. For the objects to bond together, a frequency level that is at least 20kHz is needed.
Ultrasonic welding can be used to weld materials such as plastic and metal. With the help of ultrasonic sound waves, materials can be bonded together without using screws, nails, glue, or other fastening and binding materials. Thermoplastics are welded when ultrasonic vibrations cause a melting on the materials. Melting occurs along the joint line of thermoplastics because the materials absorb the energy caused by the vibrations. When it comes to metals, the heat brought about by friction causes welding to happen.
Ultrasonic welding is perfect for mass producing items. That is because it takes a very short time to weld using this method. The shorter the welding time is, the more items are produced at a given time period. Industries like automotive industry and electronics industry have been using this welding type to manufacture products. In the automotive industry, it is used to produce electrical as well as plastic parts. In the electronics industry, ultrasonic welding is used to create mobile phone cases.
Nowadays, ultrasonic welding machines are also capable of welding semi-crystalline plastic. Unlike before when the machines can only weld metal as well as soft and hard plastic materials. Studies and tests are continuously done to know what other material types can be welded using this welding type. Experts are determining the properties of materials that are essential in achieving an excellent weld. As years go by, the demand for newer plastic and electronic products increases. Therefore, in order to produce more products at a faster phase, it is very important that studies and tests relating to ultrasonic welding are always done.
The ultrasonic welding machine used plays a very important role in the success of the weld. There are different designs of ultrasonic welding machine. There are also different manufacturers. To understand ultrasonic welding better, it is important to know the parts of an ultrasonic machine.
Ultrasonic Welding Machine Parts
An ultrasonic welding machine has many parts. One of these is the stack which has a transducer, a sonotrode or horn, and a converter. It is the part that causes vibrations. The ultrasonic welding transducer produces ultrasonic vibrations. The sonotrode is connected to the converter. It is made to vibrate at an ultrasonic frequency level. The horn is the one responsible for softening thermoplastic and heating metals.
The machine also has a press which is where the welding system is attached to. It has an anvil where parts to be welded are held.
An ultrasonic welding machine also has a generator and a controller. The ultrasonic welding generator outputs a frequency that is needed for the transducer to produce ultrasonic vibrations. It adjusts the high electric power to the right voltage. The controller is adjustable. It lets the operator adjust the speed at which the welding tool moves.
Ultrasonic welding is really a good way of welding materials. The materials are welded fast and the quality of the welding is high. For these reasons, lots of industries have been using this type of welding to produce various products.