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How do you solve common ultrasonic welding problems?
Jan 05, 2021

To use the ultrasonic welding machine correctly, following six problems must be solved:

ultrasonic welding machine.jpg

In modern industry, we can see ultrasonic welding machines everywhere. For example: product packaging, cutting, riveting, embossing, punching and other industries all need it, so a variety of ultrasonic welding with various functions has also emerged, with different application fields, usage methods and equipment requirements are very different.

The thermal resistance must reach the melting point of the workpiece:

After the ultrasonic transducer converts electrical energy into machinery, it is conducted through the material molecules of the workpiece. The acoustic resistance of ultrasonic sound waves in solids is much smaller than that in air. When the sound waves pass through the joints of the workpiece, the acoustic resistance in the gap is large. , The heat generated is quite large. The temperature first reaches the melting point of the workpiece, and a certain pressure is applied to weld the seam. The other parts of the workpiece will not be welded due to low thermal resistance.

The two workpieces must be weldable:

Some of the different materials can be welded better, some are basically fused, and some are not fused. The melting point of the same material is the same, it can be welded in principle, but when the melting point of the workpiece to be welded is greater than 350 ℃, it is not suitable for ultrasonic welding. Because ultrasound melts the molecules of the workpiece instantly, the judgment is based on the fact that it cannot be welded well within 3 seconds, and other welding processes should be selected. Such as hot plate welding. Generally speaking, ABS materials are the easiest to weld, and nylon or PP materials are the most difficult to weld.

There are certain requirements for the joint area:

When instantaneous energy is generated, the larger the joint area, the more serious the energy dispersion, the worse the welding effect, and even the failure of welding. In addition, ultrasonic waves are transmitted longitudinally, and the energy loss is proportional to the distance. Long-distance welding should be controlled within 6 cm. The welding line should be controlled between 30 and 80 wires, and the arm thickness of the workpiece should not be less than 2 mm, otherwise it will not be well welded, especially for products that require air tightness.

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