Variables to Consider In Ultrasonic Welding

The Components of Ultrasonic Welding

In ultrasonic welding, there are three variables to consider: time, pressure and amplitude. All three need to be taken into consideration to control the process. But before we delve into these considerations, let’s start with the basics. Ultrasonic welding equipment consists of a machine press, generator, converter or transducer, sonotrode or horn, component support tooling and booster.

Ultrasonic welding is basically electrical energy converted into mechanical motion, resulting in intense vibration, which creates frictional heat. The heat melts the plastic and bonds the plastic parts together. The welding machine’s horn delivers the mechanical motion. It also applies pressure until the joints solidify.

Ultrasonic welding is a great method for welding plastic parts together. However, the joint design and application of tooling are essential to ultrasonic welding success. Most ultrasonic equipment is available in 20, 30 or 40 kilohertz ratings. These are the rates at which the horn vibrates, creating a high-frequency ultrasonic acoustic vibration. The vibration causes friction, melting the plastic. Back in the 1960s, ultrasonic welding took plastic assembly to a new level. It helped to optimize design and productivity in a wide range of industries, from automobiles to cosmetics. The quality and speed of ultrasonic welding were unlike any other process, transforming plastic assembly into a more reliable, highly efficient operation.

The first industry to take advantage of this reliable welding technology was the toy business. Pioneered by Mattel and Knickerbocker, ultrasonic welding was the technology behind numerous popular toys. Later, automotive companies jumped on the bandwagon. General Motors, for example, used ultrasonic welding for turn signals and tail lights. By the early 1970s, ultrasonic welding was applied to different medical applications. Today, ultrasonic welding is used in many applications, including cell phone casings and electronic products. Ultrasonic welding is now considered the leading assembly method for rigid thermoplastics.

Learn about the inner workings of thermal assembly systems and other plastic welders at Plastic Assembly Systems, the world leader in plastic assembly solutions, by logging onto HeatStaking.com.

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