Application of ultrasonic welding
Ultrasonic welding is an industrial process in which electrical energy is converted into mechanical vibration.
High-frequency (ultrasonic) sound waves, called acoustic vibrations, are transmitted to the joint interface through plastic parts (held together under pressure). These ultrasonic vibrations generate friction and locally heat the connection area, which can cause the parts to be welded together. No other consumables are required. These two parts are ultrasonically welded to each other. The process is very fast (the cycle time is usually within 1 second) and is very energy-efficient.
In order to assemble complex thermoplastic molded parts, ultrasonic welding equipment can be easily used to connect the parts by welding. Can easily achieve firm structural welding. Customized ultrasonic tools to fit the exact specifications of the welded parts. The plastic part is sandwiched between a custom fixed sleeve (anvil) and a working horn (resonance). The operating frequency of an ordinary ultrasonic welding machine is between 20 kHz and 70 kHz. Usually, the joint interface may require a special "joint design" to help the plastic melt and flow. Ultrasonic energy will melt the contact points of the parts, resulting in welds.
Ultrasonic waves can also be used to weld metals. In applications such as "wire bonding", "spot welding" and copper tube sealing, ultrasonic metal welding is usually limited to thin "white metal". Ultrasonic weldable metals include: aluminum, copper, and nickel.
Ultrasonic welding of thermoplastics can cause local melting of the plastic due to the absorption of vibration energy along the joint line. In metals, welding occurs due to high-pressure dispersion of surface oxides and local movement of materials.
Benefits of ultrasonic welding:
Ultrasonic welding is very fast and very energy efficient. No consumables (adhesives or solvents) are required. Ultrasonic welding can be automated through easy integration into existing packaging production lines, or processing and manipulation by multi-axis robots.