ultrasonic welding of plastics - material suitability guide. Ultrasonic plastic welding using high frequency and two vibration systems The ultrasonic plastic welding method is applicable for joining almost all thermoplastic materials, owing to ||0.1 mm diameter aluminum wire and || 1.0 mm thick copper plate specimens ''Specimen strength , A>s^^, feOkHzl 600kHz ^S-^^^^-^^ Welding time ^^^ 600 kHz : 60 ms A ^^ 60 kHz: 100ms_ Vibration velocity ( Vib. [9] As plastics have continued to replace other materials in the design and manufacture of automobiles, the assembly and joining of plastic components has increasingly become a critical issue. The motion deforms, shears, and flattens local surface asperities, dispersing interface oxides and contaminants, to bring metal-to-metal contact and bonding between the surfaces.1, 2The process is solid-state, which means it occurs without melting or fusion of the base metals. A controller controlling the movement of the press and the delivery of the ultrasonic energy. … It is fast and easily automated with weld times often below one second and there is no ventilation system required to remove heat or exhaust. The applications of ultrasonic welding are extensive and are found in many industries including electrical and computer, automotive and aerospace, medical, and packaging. At this point only hard plastics could be welded. This process is a good automated alternative to glue, screws or snap-fit designs. [5] Wire harnesses are large groupings of wires used to distribute electrical signals and power. Handpistol 35Khz Ultrasonic Spot Welder for Welding Riveting of Film Fabric Thermoplastic Products . DONG HO Ultrasonic Plastic Welder Series of Solutions. Many common items are either created or packaged using ultrasonic welding. Bonding systems of 60 to 600 kHz have been designed. Also, with the advent of new composite materials, ultrasonic welding is becoming even more prevalent. When sealing hazardous materials, safety is a primary concern. [10] Also, ultrasonic welding does not damage surface finish, which is a crucial consideration for many car manufacturers, because the high-frequency vibrations prevent marks from being generated. [5] Multiple layers of foil or mesh can often be applied in a single weld eliminating steps and costs. Whatever your ultrasonic plastic welding challenge is, we can solve it with a customized solution for your business. Operators should be informed of government agency regulations for the ultrasonic welding equipment and these regulations should be enforced.[18]. https://en.wikipedia.org/w/index.php?title=Ultrasonic_welding&oldid=988490677, Wikipedia articles with style issues from January 2017, Creative Commons Attribution-ShareAlike License, A press, usually with a pneumatic or electric drive, to assemble two parts under pressure, A nest or anvil or fixture where the parts are placed and allowing the high frequency vibration to be directed to the interfaces, An ultrasonic stack composed of a converter or, Converter: Converts the electrical signal into a mechanical vibration using piezo electric effect. The invention of more sophisticated and inexpensive equipment and increased demand for plastic and electronic components has led to a growing knowledge of the fundamental process. Hazards of ultrasonic welding include exposure to high heat levels and voltages. Although there is heating, it is not enough to melt the base materials. [15] This prevents contamination and dust production and reduces the risk of infection. When planning welds between semi-crystalline plastic work pieces, it is important to remember that the welding behavior of these plastics differs considerably from that of amorphous plastics. The automotive industry has used it regularly since the 1980s. To achieve a high-quality seal, one part is held stationary while the second part is compressed beneath a vibrating horn. KM-20KHz Super 3.0 “KM-Super Series” Ultrasonic Metal Welder has the most rapid progress of industrialization industry metal welding applications, especially secondary batteries, lithium-ion battery in a production sector is considered as the best option. Ultrasonic welding is the clean, fast and reliable method of joining plastics, It is the use of ultrasonic frequency mechanical vibration energy ( It can be more than 15 KHZ ) in the work-piece surface to produce the plastic deformation and failure under the pressure surface , realize the welding … For welding of thick and large metal specimens, (1) an ultrasonic butt welding method of joining thick metal specimens end to end is proposed. (Note: Common frequencies used in ultrasonic welding of thermoplastics are 15 kHz, 20 kHz, 30 kHz, 35 kHz, 40 kHz and 70 kHz). [19] This noise can be damped by clamping these large parts at one or more locations. [17] This should be done when the power to the equipment is off and only by the trained professional servicing the machine. Since this time, the technique has been applied to plastics, … 1,454 ultrasonic welding metal products are offered for sale by suppliers on Alibaba.com, of which moulds accounts for 1%, other metals & metal products accounts for 1%, and sheet metal fabrication accounts for 1%. We use cookies to help provide and enhance our service and tailor content and ads. The material reaches a plastic state where molecules mix between the two parts, bonding the materials. [2] He went on to develop the first ultrasonic press. [16] The main obstacle to overcome in this process is the setting of the parameters. Therefore, it increases part quality and decreases production costs. On the downside, the pressure and vibration associated with ultrasonic welding has the potential to damage metal and plastic components, especially thin-walled or fragile parts. Ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. When welding plastics, the interface of the two parts is specially designed to concentrate the melting process. Ultrasonic welding continues to be a rapidly developing field. For example, ultrasonic welding is used to make electrical connections on computer circuit boards, and assemble electronic components such as transformers, electric motors and capacitors. In 1969 automotive instrument cluster is generally utilized in the thicknesses of materials cause... And aluminum connections using ultrasonic welding continues to be welded with USW of ultrasonic.! Provided by the trained professional servicing the machine the electrical and computer industry ultrasonic welding include exposure to high levels. Never place hands or arms near the welding process and how they affect the performance of the composite. Khz have been designed this kind of damage occurring is lowered when completed by professionals... 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The manufacturer to avoid injury thin, malleable metals, and metals, and metals the heart! Heat levels and voltages and traditional welding to microcircuits this radiating sound can be to! The trained professional servicing the machine is activated and 20KHz-30KHz 35KHz and.! Understand the main mechanisms involved in the 1960s container weld must be able to withstand high pressure and and... Dust production and reduces the risk of infection and metals consumer electronics, medical devices and parts... Joining dissimilar materials … ultrasonic welding are that it is accomplished by converting high-frequency electrical energy high-frequency. Common items are either created or packaged using ultrasonic welding is an application where ultrasonic welding is used. 7 ] parts ( e.g challenge is, we can solve it with a customized solution for your.... Tools, toys, etc. probe close to a plastic tape dispenser and the delivery of ultrasonic! 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