​Material Selection Of Ultrasonic Mold

​Material Selection Of Ultrasonic Mold

Date:Mar 25, 2021


Material selection of ultrasonic mold


The service life of ultrasonic molds is critically determined by three aspects:

a. Material,

b. Process  

c. Shape design (Inappropriate shape design will cause stress concentration of sound wave transmission, and severely cause ultrasonic mold rupture)


Material aspect: Ultrasonic molds require metal materials to have good flexibility (small mechanical loss during sound wave transmission), so the commonly used materials are aluminum alloy and titanium alloy


The material is one of the main reasons to ensure the life of the ultrasonic mold and the effect of the welded product. The completion process of the ultrasonic mold is complicated. Therefore, it is not only the design of ultrasonic mold engineers that must carefully choose the material, but also need to understand what kind of material should be used in their products, so as to avoid negligence to affect its timeliness and quality.


The current characteristics of various materials are summarized as follows:

 A. Aluminum-magnesium alloy (7075-T651, 2024-T651, 6061-T651)

 7075T651: Used in vibration systems and Horn manufacturing. This material has extremely high mechanical yield strength, high hardness, and strong thermal conductivity. It is an ideal ultrasonic mold manufacturing material;


 2024T651: generally made of HORN, with good bremsstrahlung, strong thermal conductivity, moderate hardness, used for general plastic products;


 6061T651: Used in the manufacture of ultrasonic welding heads with lower output, with good bremsstrahlung and softer quality;



  B. Titanium alloy: It is a machine type used for continuous vibration, with high bremsstrahlung, good heat conduction, high hardness, and high cost.



  C. Domestic hard aluminum alloy: domestic material, used for ordinary aluminum processing, low heat conduction, high mechanical loss of ultrasonic, and low cost.



When purchasing ultrasonic molds, users need to consider the following factors:

1. Product requirements: determine the service life and wear rate of ultrasonic molds, and therefore determine which metal to use.

2. The shape of the product: What kind of welding process is used, the size of the mold, the pressure transmission area, the possible deformation of the product during fusion, how much power and what function is required. Is it possible to complete the work in one fusion splicing.

3. The plastic properties of the product: determine the working amplitude of the mold, which piece of work should receive ultrasonic energy, the form, position and size of the energy-conducting wire. How to design the contact position in different plastic combinations?

4. High-quality after-sales service, we can't give up near and far, and we can't just ask for price.


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