Pdf polymer adhesion by ultrasonic welding researchgate. Ultrasonic welding usw is a promising method for the. Intelligent assembly solutions guide to ultrasonic. Ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. Ultrasonic plastic welding machine auto ultrasonic power. A checklist can help decide whether plastic welding is a good fit. Ultrasonic heat is created during the vibration phase of the process upon the application of pressure and a vibration frequency ranging from 10 khz 70 khz to 10 25 0 mm per pendicular to the parts to be welded 2. When in doubt, contact a supplier of welding equipment for advice.
Thus assembly of subcomponents is critical for manufacturing of many products. Figure 11 shows the ultrasonic welding process in more detail. The frequency of acoustic vibrations is in the range 20 to 70 khz commonly 2040 khz. Ultrasonic welding ultrasonic welding is a unique method of joining two parts together without using additional fasteners, adhesives or mechanical features like snap fit or living hinges. Naruse 105 carried out ultrasonic plastic welding using a surface acoustic. For many plastic assemblies ultrasonic welding is a better joining method than fasteners or adhesives. General as with ultrasonic welding and inserting, ultrasonic staking employs the same principles of creating localized heat through the application of highfrequency vibrations. It is commonly used for plastics and metals, and especially for joining dissimilar materials. The key to successful ultrasonic welding is appropriate material selection and part design. Ultrasonic welding is a method of joining thermoplastic components by heating and subsequent melting of surfaces in contact. During the welding cycle, the concentrated ultrasonic energy causes the ridge to melt and the plastic to flow throughout the joint area, bonding the parts together. Ultrasonic welding ultrasonic welding is the most common application of ultrasonic assembly. The advantage of using this technique with plastics is that within seconds a high strength, gas and water tight bond is formed without screws, glue, threads, solder or any other type of bonding.
Ultrasonic welding of thermoplastics white rose etheses online. Ultrasonic welding of thermoplastic materials is by far the most common form of ultrasonic assembly, and is used extensively in all major industries including. As a joining process for industrial thermoplastics, the. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary. Advantages of ultrasonic plastic welding the ultrasonic welding technology sets itself apart with fast welding speeds, high welding strength and good sealing performance. Welding recommendations optimum ultrasonic welding conditions are very dependent upon the assembly being welded and the welding equipment being used. It is frequently chosen when parts are too complex or expensive to be molded in one piece. The 2000xc locks in the welding process with fully electronic welder settings. Each ultrasonic welding installation comprises the following main components. Ultrasonic welding is a plastics welding process, in which two work pieces are bonded as a result of a pressure exerted to the welded parts combined with. Ultrasonic welding usw is a solidstate welding process that produces a weld by local application of high frequency vibratory energy. One of the most modern welding methods is ultrasonic welding technology, which has various applications in the engineering industry. Ultrasonic welding solutions for the plastic packaging industry.
The basics of ultrasonic plastic welding technology. Ultrasonic welding is an industrial technique whereby highfrequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solidstate weld. Technical data sheet of the ultrasonic generator smalld40. Ultrasonic plastic welding is, in principle, the joining of thermoplastics through the use of heat generated from high frequency mechanical motion. Ultrasonic plastic welding machine ultrasonic plastic. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam.
Ultrasonic energy has been used to join thermo plastics for over 35 years. The most simple way of welding thermoplastic materials to use the ultrasonic manual welding device. When the vibrations stop, the plastic solidifies and the two workpieces are bonded together. Introduction 0 there are many products too complex to model as a single part. Frictional heat is produced so that thermoplastic parts melt and an insoluble connection between parts is forged in a. It is accomplished by converting high frequency electrical energy into high frequency mechanical motion. Reliable hiq ultrasonic welding technology from herrmann. To achieve a constant quality the welding time is automatically adjusted. That mechanical motion, along with applied force, creates frictional heat at the plastic. The operation of an ultrasonic welder can be described. Technical data sheet of the ultrasonic welding press model estr1 20. Aside from the joint design, other aspects of the moulded component must be considered if ultrasonic welding is to be effective. Ultrasonic welding is well suited for a large number of automotive components, where high part counts and appropriate strength are required.
Pdf potential pitfalls in ultrasonic plastic welding researchgate. Whether you choose our most fully featured 2000x d, the advanced functionality of the 2000x ea, or the basic features of. The 2000xc combines precise and consistent high quality welds, fast cycle times, and the process control needs of todays manufacturing environment. The technique, ultrasonic welding, used highfrequency sound waves and pressure to bond metals together and required less energy than conventional welding. The direct welding characteristics of an ultrasonic plastic welding system with an upper 90 khz longitudinal welding tip with a small vibration amplitude and a lower 20 khz low frequency torsional. Introduction to ultrasonic plastic welding, application setup and troubleshooting improve your companys production by learning from the industrys experts and getting handson training of the fundamentals of ultrasonic welders. Compared with other welding methods which include heat staking, hot plate welding, spin welding, and vibration. Welding characteristics and temperature rises at plastic welding part over frequency range from 27 khz to 180 khz were studied. The process is c lean because it doesnt use harmful solvents or glues while also not damaging the. Many staking applications involve the assembly of metal and plastic components. The vibrations move through the part and creates friction at the interface. Ultrasonic vibration transmitted by a metal tool horn, sonotrode causes oscillating flexing of the. Ultrasonic energy has been used to join thermoplastics for over 70 years.
Ultrasonic metal welding developed during the 1950s through the 1990s as the electronics used in the equipment became more sophisticated and computers could control the process. After ultrasonic energy is turned off, the parts remain in contact under pressure for some time while the melt layer cools down creating a weld. It is accomplished by converting highfrequency electrical energy into highfrequency mechanical motion. Ultrasonic welding, for thermoplastic injection moulded components, is a process that uses. Ultrasonic welding component design and weld parameters. Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from highfrequency mechanical motion. Ultrasonic welding, energy director shapes, joint strength, thermoplas tic polymers, composites 1.
Separate areas, numerous welding and riveting connections, and various joining directions can be welded in parallel. In ultrasonic welding, the heat required to melt the moulds is created by converting ultrasonic vibrations into mechanical vibrations and guided to the work piece to be welded at a certain contact pressure through the sonotrode. The nn technique is used to find the importance of individual control parameter. Ultrasonic welding is found everywhere where thermoplastics are used and strict demands are placed on the method of joining. Although this type of quality control is good with ultrasonic plastics welding, the approach has to be. Plastic welding, ask latest information, plastic welding abstract,plastic welding report,plastic welding presentation pdf,doc,ppt,plastic welding technology. The plastic melts in the contact area, the polymer molecules are crosslinked, forming a strong joint. The ampltude of the acoustic vibrations is about 0. Ultrasonic welding process is widely used in the microelectronics devices and finishing technology, the most successful application is the integrated circuit element of interconnection and it is used in the electronic aerospace electrical packaging plastic industries. In handbook of plastics joining second edition, 2009. Introduction for bonding plastics and composites often use welding technologies. Ultrasonic welding of plastics herrmann ultrasonics. Plastic welding ultrasonic plastic welding system it is hard to imagine how the requirement for quality and reliability of welds, econom y and the ecological demand placed on todays production methods could be met without the modern production engineering of ultrasonic w elding.
Fundamentals of ultrasonic plastic welding machine design. This paper discusses the weldability of similar and dissimilar thermoplastics with the use of ultrasonic welding and compares the experimental. Ultrasonic welding process welds thin to thick material combinations, it is. The distance between the joint line and the contact surface where the welding horn meets the component can be critical. Compared with other welding methods, ultrasonic welding is particularly suitable where rapid process times, coupled with good process reliability are demanded or if no other fillers or solvents are to be used. Branson 2000x series ultrasonic assembly systems offer you a range of system models with varying process control levels and functionalities to match your application needs. The application areas can be seen here at a glance. Modeling, sensing and control of gas metal arc welding, 2003. In ultrasonic plastic welding, a vibratory motion at the horn face amplitude is transferred to the part.
Ultrasonic welding an overview sciencedirect topics. This is a suitable replacement for traditional weldingbonding processes. Contents 0 introduction 0 classification of plastic welding 0 hot plate welding 0 hot gas welding 0 ultrasonic welding 0 friction welding 0 laser welding 0 conclusion 0 references 3. It offers many advantages, including process reliability and repeatability, lower energy usage than other joining techniques, material savings because there is no need for consumables, such as glue or mechanical fasteners, and labor savings. Mechanical vibration with frequency between 10 and 70 khz and amplitude of 10 to 250. The plastic components function here as the energy carriers. Ultrasonic plastic joining technical information pw3 part design for ultrasonic welding ultrasonic energy has been used to join thermo plastics for over 35 years. An ultrasonic seam welding system consists of a complex vibration disk welding tip which is driven by a longitudinal vibration system through a longitudinaltorsional vibration converter. Extremely short process times, thanks to electrical vibrations in the ultrasonic range. Pdf ultrasonic welding is fast, requires no consumables, and can be applied to a wide variety of applications. These include many parts made of thermoplastic materials for interior and exterior applications, and engine compartments, but also of nonferrous metals for cable harnesses and lithiumion batteries.
It produces a strong joint while avoiding any mess or additional components. Ultrasonic plastic welding can be used for practically all thermoplastics. In welding, the horn is brought into contact with one of the workpieces, pressure is applied and vibrating ultrasonic energy. The 4200w ultrasonic plastic welding machine we professionally produce standard ultrasonic plastic welding machine, such as 2600 w 3200 w plastic welding machine, 4200 w 5600 w high power plastic welding machine and other precision welding equipment. While it is important to seek the advice of the manufacturer of the ultrasonic welding equipment in determining the best possible process setup, the following general comments about ultrasonic welding. Frequency characteristics of ultrasonic plastic welding jstage. Dont forget to download a copy of lpkfs laser plastic welding design guidelines, a document for engineers and designers in the concept and design stage of an application. An introduction to the ultrasonic welding of plastics.
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