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