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How does an Ultrasonic welder work? An Ultrasonic welder is a machine that uses kinetic energy from vibrations to heat and melt plastic together. The basic process comes down to a vibration frequency, measured in hertz, directing energy onto a section of the 2 parts you want to weld together.
The parts that are being welded are placed between the nest (commonly known as the anvil) and the sonotrode (commonly known as the horn). Both the horn and the nest is usually made from aluminium or titanium. The sonotrode is the connected to a transducer which emits the acoustic vibration. This vibration flows from the transducer, down the horn, and onto the part that is being welded. The frequency of the vibration can range from 15kHz all the way up to 70kHz.
The part design is usually critically. That part that contacts the horn, usually has a triangular lip that is protruding from the face that is being welded. The other part, that is contact with the nest, is held still and has a small groove that meets the protruding lip on the other part. The energy is concentrated into this lip, which is then heated and melted by the vibrations, and at a certain point this lips’ structure collapses and fills the groove with molten plastic.
Therefore, the ultrasonic horn is the part that directly works with the weldment, and the design of the ultrasonic horn affects the welding effect of the weldment. At the same time, the ultrasonic horn also belongs to the consumables in the entire welding system. Generally, the transducer and the ultrasonic power supply can work for 5 to 10 years, but the ultrasonic horns is available for several months to several years according to different working conditions.
How to choose material for different application:
Aluminum alloy ultrasonic horn are suitable for discontinuous high-intensity friction operations such as stitching and welding, high ultrasonic wave intensity, and the surface of the mold needs to be engraved (such as ultrasonic plastic welding machines, mask setting machines, ultrasonic quilting machines, etc.) Equipment), aluminum alloy is available.
Aluminium alloy advantages: light weight, low density; high ultrasonic transmission rate, suitable for large mold; hardness is not high, the mold can be carved with more complex patterns, but its disadvantages are not high wear resistance, easy to wear.
Titanium alloy ultrasonic horn is suitable for working places with higher ultrasonic transmission rate, larger working surface, and also need better wear resistance.
The advantages are high hardness, good abrasion resistance, fast heat dissipation, light weight, and low density. When ultrasonic waves of the same power are transmitted, the ultrasonic transmission rate of the same volume mold is higher than that of the steel mold. It can be said that the titanium mold integrates many advantages of the steel mold and the aluminum mold, and the cost is higher. The price of the titanium mold is much higher than the aluminum mold and steel mold of the same specification.
Steel ultrasonic horn is more suitable for various rolling, punching, slitting, cutting and other application equipment, such as mask body machine, ultrasonic cloth slitting machine, ultrasonic punching machine and many other equipment use steel mold.
Advantages: high hardness, high wear resistance, the strongest mold life, high stability. The disadvantage is that the ultrasonic transmission rate is relatively low and the acoustic impedance is large. In order to ensure the ultrasonic transmission effect, it is not suitable for the large size of the mold. For a round mold, the unit diameter cannot generally exceed 11.5cm.
It can be seen from this that what kind of material to use depends on the use occasion and application of the ultrasonic equipment and the welding requirements of the product. Customers and friends can make appropriate choices according to different situations.
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