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Ultrasonic/Vibration/Hot Gas Welding

Ultrasonic/Vibration/Hot Gas Welding. Presented by: Kevin Himes Marty Timm James Scott. Ultrasonic Welding. Basic Purpose & Process Produce hermetic bonded joints Mechanical movement High frequency sound energy Oscillating horn 20 to 40 KHz Very quick cycles. Ultrasonic Welding.

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Ultrasonic/Vibration/Hot Gas Welding

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  1. Ultrasonic/Vibration/Hot Gas Welding Presented by: Kevin Himes Marty Timm James Scott The Pennsylvania State University at Erie The Behrend College

  2. Ultrasonic Welding • Basic Purpose & Process • Produce hermetic bonded joints • Mechanical movement • High frequency sound energy • Oscillating horn • 20 to 40 KHz • Very quick cycles

  3. Ultrasonic Welding • Equipment

  4. Ultrasonic Welding • Types of Joining • Welding • Staking • Inserting • Swaging • Spot Welding • Slitting • Textile/Film Sealing

  5. Ultrasonic Welding • Welding Parameters • Weld – by – Time • Weld – by – Energy • Weld – by Collapse Distance

  6. Ultrasonic Welding

  7. Ultrasonic Welding

  8. Ultrasonic Welding • Appliances • Automotive • Electrical • Medical • Packaging • Toys

  9. Ultrasonic Welding • Materials • Most Thermoplastics • Stiffer easier to weld • Higher melt temperatures require more energy • Similar molecular structures • Crystalline only weldable to themselves

  10. Ultrasonic Welding • Advantages • Energy efficiency • High productivity with low costs • Ease of automated assembly lines • Fast joining times

  11. Ultrasonic Welding • Disadvantages • Limited component length of 250mm • Bondable materials

  12. Vibration Welding • Basic Purpose and Process • Produce strong, pressure-tight welds • Rubbed together under pressure • Suitable frequency and amplitude • 100-500 Hz • 1-4 MPa pressure • 1-5 mm amplitude • Rapid cycles

  13. Vibration Welding

  14. Vibration Welding • Materials • Both amorphous and semicrystalline • Injection molded, extruded, blow molded, thermoformed, or stamped • Crystalline thermoplastics • Acetal, polyethylene, nylons and polypropylene

  15. Vibration Welding • Typical Applications • Automotive • Aerospace • Appliance • Medical • Electrical / Electronic • Recreational

  16. Vibration Welding • Advantages • Large complex linear joints • Applicable to most polymers • High production rates • Number of components simultaneously • Simplicity of tooling

  17. Vibration Welding • Disadvantages • Materials with similar melt temps • Limited part geometry

  18. Vibration Welding • New advancements • Ability to vary pressure during cycle • Development of equipment or orbital welding

  19. Hot Gas Welding • Process • Hot gas • Two thermoplastic materials • Filter rod

  20. Hot Gas Welding • Equipment • Heater unit • Nozzle • Remote air compressor or integral blower

  21. Hot Gas Welding • Two main types • Speed Welding • Round Nozzle Welding

  22. Hot Gas Welding

  23. Hot Gas Welding • Advantages • Cheap • Simple equipment • Simple Operation

  24. Hot Gas Welding • Disadvantages • Limited Materials • Lower Strength

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