1. Ultrasonic Welding Presented by: Ryan Alexander Chris Baker Jon Stempka

2. Purpose Ultrasonic device and components Ultrasonic device and components Basic operation Basic operation Applications Applications Advantages and disadvantages Advantages and disadvantages Types of material Types of material Other welding Techniques Other welding Techniques

3. Types of Welds Friction weld Friction weld Cold press weld Cold press weld Ultrasonic weld Ultrasonic weld Use of binder material Use of binder material

4. Hot Gas Welding Less common Less common Uses hot gas to create localized melt Uses hot gas to create localized melt Binder material added Binder material added

5. Advantages Simple equipment Simple equipment Simple Operation Simple Operation Low Cost Low Cost

6. Disadvantages Limited Materials Limited Materials Limited part geometry (sheet joining) Limited part geometry (sheet joining) Lower strength Lower strength

7. Ultrasonic welding of plastic Vibrations Vibrations Local Plastification Local Plastification Melting points must be equal Melting points must be equal

8. Welding equipment Ultrasonic generator Ultrasonic generator Ultrasonic welding device Ultrasonic welding device Ultrasonic transducer system Ultrasonic transducer system Anvil and fixtures Anvil and fixtures

9. Ultrasonic generator 20 KHZ 20 KHZ 35 KHZ 35 KHZ 40 KHZ 40 KHZ Required holding and welding time Required holding and welding time

10. Ultrasonic welding device 1. Sonotrode 1. Sonotrode 2. High-tensile threaded pin 2. High-tensile threaded pin 3. Height adjustment 3. Height adjustment 4. Converter 4. Converter 5. Oscillating disk 5. Oscillating disk 6. Booster 6. Booster

11. Ultrasonic transducer system Converter Converter Booster Booster Sonotrode Sonotrode

12. Anvil and Fixture Typical example of sonotrode and fixture

13. Welding Parameters Welding Energy Welding Energy Mechanical Stress Mechanical Stress Thermal Stress Thermal Stress

14. Welding Energy Contact pressure Contact pressure Welding time Welding time Trigger point Trigger point Amplitude Welding tools Ultrasonic frequency

15. Mechanical Stress Amplitude Amplitude Mechanical pressure Mechanical pressure

16. Thermal stress Welding time Welding time Amplitude Amplitude Mechanical pressure Mechanical pressure

17. Quality control Changeable process- variable parameters Changeable process- variable parameters Similar characteristics Similar characteristics Parameter control Parameter control

18. Changeable process-variable parameters Weld time Weld time Weld energy Weld energy Mechanical compression of the parts to be welded Mechanical compression of the parts to be welded

19. Mechanical Compression Wrongly positioned parts Wrongly positioned parts Selection of wrong parts Selection of wrong parts Strongly contaminated parts Strongly contaminated parts Deficiencies in welding equipment Deficiencies in welding equipment

20. Welded parts should have similar characteristics Chemical Chemical Mechanical Mechanical Process Process

21. Typical ultrasonic welded plastics PS to PS PS to PS Nylon to Nylon Nylon to Nylon PP to PP PP to PP Compatible plastics such as Compatible plastics such as ABS to PS ABS to PS SAN to ABS SAN to ABS

22. Parameter control Tool dimension Tool dimension Weld pressure Weld pressure Trigger point Trigger point Amplitude Amplitude

23. Advantages Clean, reliable, consistent, and affordable process Clean, reliable, consistent, and affordable process No pre-weld or post-weld operations No pre-weld or post-weld operations Low consumption of energy Low consumption of energy Rapid repeatable process (often less than 1 second) Rapid repeatable process (often less than 1 second) Long tool life Long tool life

24. Disadvantages Plastics must have similar characteristics Plastics must have similar characteristics Tool design required Tool design required Joints maybe weakened by incomplete fusion Joints maybe weakened by incomplete fusion

25. Applications Automotive Automotive Toys Toys Appliances Appliances Medical Medical

26. Automotive The average new car has over 100 ultrasonic welded parts The average new car has over 100 ultrasonic welded parts

27. Toys Typical examples Typical examples Plastic and steel ultrasonic welding Plastic and steel ultrasonic welding

28. Medical Must be a precision weld to obtain FDA approval Must be a precision weld to obtain FDA approval Used because it is a clean process Used because it is a clean process

29. Appliances Used in many every day household items Used in many every day household items

30. Conclusion Can be used for many applications Can be used for many applications Clean, reliable, consistent, and affordable process Clean, reliable, consistent, and affordable process Can be used with metal as well as plastic Can be used with metal as well as plastic Quality control can be used in this process Quality control can be used in this process