Introduction To The Working Process Of Ultrasonic Welding
Ultrasonic welding work process
The two plastic parts to be joined are assembled in a nest (anvil or fixture)
The horn is in contact with the upper part of the sheet.
The pressure on the two components is applied to the fixture. The pressure is applied by a pneumatic or electric press.
The horn vibrates vertically at very high frequencies (20 kHz to 40 kHz), transmitting mechanical vibrations to the two plastic parts. This creates thermal energy at the contact tips of the two surfaces and causes them to melt.
A clamping force is applied to the two components for a predetermined time to fuse them together to form a strong weld upon cooling and solidification.
After solidification, the clamping force is removed and the horn is retracted. The welded plastic parts are removed from the fixture as a whole.
Application
It is mainly used in the computer and electrical, aerospace and automotive, medical and packaging industries.
Computer and electrical industry
Here it is used to connect wired connections and establish connections in small precision circuits.
Aerospace and automotive industry
In the automotive industry, it is used to assemble large plastic and electrical components such as door panels, instrument panels, air ducts, lights, steering wheels, and interior and engine components.
Aerospace industry
In the aerospace industry, it is used to join thin gauges and lightweight materials such as aluminum.
Medical industry
It does not introduce any contaminants or degradation into the weld. This is why it is used in the medical industry.
Anesthesia filters, arterial filters, blood filters, dialysis tubes, pipettes, blood/gas filters, cardiac measuring containers, etc. can be manufactured using ultrasonic welding methods.
Packaging industry
It is used to package different materials for the food industry.
It is used to package hazardous materials such as explosives, fireworks and chemicals.
Benefit
This is a fast welding process.
It has a fast drying time, ie drying of parts that do not dry for a long time in the fixture
It can be easily automated.
It produces clean and precise joints.
It has a clean welding position that does not require and repair work.
It has a low heat impact on the material.
