9/14/2013 0 Comments Ultrasonic Welding ProcessUltrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. It is commonly used for plastics, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. Sonoband Ultrasonics” developed the first machine. In those days, the company was referred to as Aero projects”. It is an industrial technique where high frequency ultrasonic acoustic vibrations are locally applied to work pieces. They are being help together under a state of sphere to create a solid state of weld. The greatest part here is that there are no connective bolts nails or any soldering materials that are needed to bind these materials together. It is nothing but solid pressure, which is used to bind them together. Now if ever in the course of work you feel that you have to join plastics or any dissimilar material you know you are in need of Ultrasonic metal welders ultrasonic metal welders. Ultrasonic welding as a process to join to materials has its history way back in the year 1960.This is a system, which is used to join complex injection molded thermoplastic parts. The parts, which are to be welded, are sandwiched between a fixed shaped nest and a sonotrode are connected to a transducer. Then a - 2020 KHZ low amplitude acoustic vibration is emitted. The main job fill rite of the welder is to design the interfaces of the two parts are specially designed to concentrate on the melting process. Thermoplastics are ultrasonically welded and it causes melting of local plastic. The welding takes place due to the vibrations. This form of welding occurs due to high pressure dispersion of surface oxides and local motion of materials. Although you have a bit of heating but it is not enough to melt base materials. You have vibrations, which are introduced after the joints have been welded. This is a form of welding which can be used for both hard and soft plastic. For joining complex injection molded thermoplastic parts, ultrasonic welding equipment can be easily customized to fit the exact specifications of the parts being welded. The parts are sandwiched between a fixed shaped nest (anvil) and a sonotrode (horn) connected to a transducer, and a ~20 kHz low-amplitude acoustic vibration is emitted. (Note: Common frequencies used in ultrasonic welding of thermoplastics are 15 kHz, 20 kHz, 30 kHz, 35 kHz, 40 kHz and 70 kHz). When welding plastics, the interface of the two parts is specially designed to concentrate the melting process. One of the materials usually has a spiked energy director which contacts the second plastic part. The ultrasonic energy melts the point contact between the parts, creating a joint. This process is a good automated alternative to glue, screws or snap-fit designs. It is typically used with small parts (e.g. cell phones, consumer electronics, disposable medical tools, toys, etc.) but it can be used on parts as large as a small automotive instrument cluster. Ultrasonics can also be used to weld metals, but are typically limited to small welds of thin, malleable metals, e.g. aluminum, copper, nickel. Ultrasonics would not be used in welding the chassis of an automobile or in welding pieces of a bicycle together, due to the power levels required.
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