Ultrasonic,Welding,Overview,Ul technology Ultrasonic Welding Overview
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Ultrasonic Welding is a process where the high frequency vibrations ofan ultrasound are applied to a piece that is to be welded. The pieces are putunder pressure and held together until they create what is know as a solidstate weld. Usually there needs to be a frequency between 20 and 40kHz in orderfor this to work. This type of weldingis used for plastics and for joining two different materials. By using an ultrasonic vibration there is no need for bolts, nails,soldering or adhesives to keep the materials together. By using thesevibrations on thermoplastics melting occurs on the plastic as it pulls in theenergy of the vibration, which is pulled across the joint that needs to bewelded. On metals, ultrasonic welding happens when the material is takenthrough friction welding. The vibrations from the ultrasonic welding machine are produced by awelding sonotrode (horn) and they soften the thermoplastic material along theline of the joint. The equipment that is used will determine how strong theweld is and this will depend on how the equipment is designed, the materials tobe welded and their properties and how the joint is designed. The time it takes ultrasonic welding to happen is very short and formass production this type of welding works very effectively. This type ofwelding will be used in the automotive industry for light clusters of thingsthat need done and in producing electronic products like the casings in mobilephones. Ultrasonic welding is used toweld both hard plastics and soft plastics and some metals. Today the machinesare able to even do semi crystalline types of plastics. There is research andtesting going on to see how this process works because not everyone hasunderstood the power of this process. They are studying areas like how theprocess parameters of something to be welded with relate to the quality of theweld. The process has needed to be studied because there has been more of ademand for different types of plastics and for electronic pieces which are bestmade by this process. In many respects it is still a developing field. Ultrasonic welding is made up of several components. Some of thesecomponents are: · It needs a press that can hold two different partsthat will be put under pressure.· An anvil to put the parts in place to take on theelevated frequency vibration that is needed to hit the pieces. · Something called an ultrasonic stack that has aconverter that holds the horn that needs to be tuned to the specific frequency.· An electronic ultrasonic generator that can deliver ahigher power AC signal that can match the frequency that matches the resonanceof the stack.· A controller that can control the movement that thepress will make and how it delivers the ultrasonic energy. Ultrasonic welding can be found in many different areas beyondelectronics and the automotive industry. This process is also used in theelectrical area, with computers, with aerospace and with the packing andmedical industries.
Ultrasonic,Welding,Overview,Ul