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Ultrasonic Welding

Ultrasonic Welding . Presented by: Ryan Alexander Chris Baker Jon Stempka. Purpose. Ultrasonic device and components Basic operation Applications Advantages and disadvantages Types of material Other welding Techniques. Types of Welds. Friction weld Cold press weld Ultrasonic weld

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Ultrasonic Welding

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  1. Ultrasonic Welding Presented by: Ryan Alexander Chris Baker Jon Stempka

  2. Purpose • Ultrasonic device and components • Basic operation • Applications • Advantages and disadvantages • Types of material • Other welding Techniques

  3. Types of Welds • Friction weld • Cold press weld • Ultrasonic weld • Use of binder material

  4. Hot Gas Welding • Less common • Uses hot gas to create localized melt • Binder material added

  5. Advantages • Simple equipment • Simple Operation • Low Cost

  6. Disadvantages • Limited Materials • Limited part geometry (sheet joining) • Lower strength

  7. Ultrasonic welding of plastic • Vibrations • Local Plastification • Melting points must be equal

  8. Welding equipment • Ultrasonic generator • Ultrasonic welding device • Ultrasonic transducer system • Anvil and fixtures

  9. Ultrasonic generator • 20 KHZ • 35 KHZ • 40 KHZ • Required holding and welding time

  10. Ultrasonic welding device • 1. Sonotrode • 2. High-tensile threaded pin • 3. Height adjustment • 4. Converter • 5. Oscillating disk • 6. Booster

  11. Ultrasonic transducer system • Converter • Booster • Sonotrode

  12. Anvil and Fixture • Typical example of sonotrode and fixture

  13. Welding Parameters • Welding Energy • Mechanical Stress • Thermal Stress

  14. Contact pressure Welding time Trigger point Amplitude Welding tools Ultrasonic frequency Welding Energy

  15. Mechanical Stress • Amplitude • Mechanical pressure

  16. Thermal stress • Welding time • Amplitude • Mechanical pressure

  17. Quality control • Changeable process-variable parameters • Similar characteristics • Parameter control

  18. Changeable process-variable parameters • Weld time • Weld energy • Mechanical compression of the parts to be welded

  19. Mechanical Compression • Wrongly positioned parts • Selection of wrong parts • Strongly contaminated parts • Deficiencies in welding equipment

  20. Welded parts should have similar characteristics • Chemical • Mechanical • Process

  21. Typical ultrasonic welded plastics • PS to PS • Nylon to Nylon • PP to PP • Compatible plastics such as • ABS to PS • SAN to ABS

  22. Parameter control • Tool dimension • Weld pressure • Trigger point • Amplitude

  23. Advantages • Clean, reliable, consistent, and affordable process • No pre-weld or post-weld operations • Low consumption of energy • Rapid repeatable process (often less than 1 second) • Long tool life

  24. Disadvantages • Plastics must have similar characteristics • Tool design required • Joints maybe weakened by incomplete fusion

  25. Applications • Automotive • Toys • Appliances • Medical

  26. Automotive • The average new car has over 100 ultrasonic welded parts

  27. Toys • Typical examples • Plastic and steel ultrasonic welding

  28. Medical • Must be a precision weld to obtain FDA approval • Used because it is a clean process

  29. Appliances • Used in many every day household items

  30. Conclusion • Can be used for many applications • Clean, reliable, consistent, and affordable process • Can be used with metal as well as plastic • Quality control can be used in this process

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