8/17/2019 Ultrasonic Welding Process - Working Principle, Parts, Advantages and Disadvantages with Application - The Welding Master
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Ultrasonic Welding Process –
Working Principle, Parts, Advantages
and Disadvantages with Application
May 10, 2017 tvm@2017 0 Comments
Ultrasonic Welding (USW) is a
welding technique which uses
ultrasonic vibration of high
frequency to weld the two pieces
together. It is most commonly Search
used to weld thermoplastic
materials and dissimilar materials. Search
Metal with thin section can also be
welded with USW.
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A high frequency (20 kHz to 40 kHz) ultrasonic vibration is used to join two
Works?
plastic pieces together. The high frequency vibration generates heat energy at
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the interface of the two pieces and melts the material. The melted material
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fused with each other to form a strong weld on cooling and solidi cation.
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8/17/2019 Ultrasonic Welding Process - Working Principle, Parts, Advantages and Disadvantages with Application - The Welding Master
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The typical frequency used is 15, 20, 30, 35 or 40 kHz. Uncategorized
Welding
Main Parts What is
The various main parts or components of ultrasonic welding are
1. A Press: It is used to apply pressure on the two plastic pieces to be
joined. It may be of pneumatic or electric driven type.
2. Nest or anvil or xture: It is a clamping device which is used to hold
and clamp the two plastic pieces together. It allows the high
frequency vibration directed to the interface of the two pieces.
3. An Ultrasonic Stack: It consists of the three components, a
converter or piezoelectric transducer,a booster and a horn or
sonotrode. These three elements are tuned to work on resonate
frequency of 15 kHz, 20 kHz, 30 kHz, 35 kHz or 40 kHz.
Converter: It converts the electrical signals into high frequency
mechanical vibration. And it does so through piezoelectric e ect.
Booster: It modi es the amplitude of vibration mechanically. In
some standard systems, it is used to clamp the stack in the press.
Horn or Sonotrode: It vibrates at high frequency and transmits the
mechanical vibration to the two pieces to be welded. It also modi es
the amplitude mechanically. It takes the shape of the part. The horn
is made of titanium or aluminum.
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8/17/2019 Ultrasonic Welding Process - Working Principle, Parts, Advantages and Disadvantages with Application - The Welding Master
4. An Ultrasonic Generator: It generates and delivers high frequency
electrical signal matching the resonance frequency of the stack.
5. Controller: It is used to control the movement of the press and
delivery of the ultrasonic energy.
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Advantages and Disadvantages
Working Process of Ultrasonic
Welding
The two plastic pieces to be joined is assembled in the nest ( anvil or
xture)
The horn is made to contact at upper part of the piece.
A pressure is applied on the two pieces against the xture. The
pressure is applied through the pneumatic or electric driven press.
Horn is vibrated vertically at very high frequency (20 kHz to 40 kHz),
transmits the mechanical vibration to the two plastic pieces. This
generates heat energy at contact tip of the two surfaces and melts
them.
A clamping force is applied on the two pieces for a predetermined
amount of time to fuse them together to form a strong weld on
cooling and solidi cation.
After solidi cation, the clamping force is removed and horn
retracted. The welded plastic part is taken out of the xture as one
piece.
Application
It is mostly used in computer and electrical, aerospace and automotive,
medical, and packaging industries.
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8/17/2019 Ultrasonic Welding Process - Working Principle, Parts, Advantages and Disadvantages with Application - The Welding Master
1. Computer and Electrical Industries: Here it is used to join wired
connections and to create connections in small delicate circuits.
2. Aerospace and Automotive Industry
In automotive industries it is used to assemble large plastic and electrical
components such as door panels, instrument panels, air ducts, lamps,
steering wheels, and upholstery and engine components.
In aerospace it is used to join thin sheet gauge and lightweight materials
like aluminum.
3. Medical Industry
It does not introduce any contaminants or degradation into the weld.
That’s why it is used in medical industries.
Items such as anesthesia lters, arterial lters, blood lters, dialysis tubes,
pipettes, blood/gas lters, cardiometry reservoirs etc. can be made using
ultrasonic welding method.
4. Packaging Industry
It is used to package di erent materials in food industries.
It is used for packaging dangerous materials like explosives, reworks and
chemical.
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Principle with Diagram
Advantages
It is fast welding process.
It has Quick drying time i.e. the pieces do not remain for a long time
in the xtures to dry
It can be easily automated.
It produces clean and precise joint.
It exhibits clean weld sites and does not require and touch-up work.
It produces low thermal impact on the materials.
Disadvantages
It cannot be used to produce large joints (greater than 250 x 300
mm).
It requires especially designed joints, so it can make tip contact
during welding process.
High tooling cost for the xtures.
Ultrasonic welding process is restricted to the lap joints.
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8/17/2019 Ultrasonic Welding Process - Working Principle, Parts, Advantages and Disadvantages with Application - The Welding Master
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