What is the application of ultrasonic welding principle in process to non-metal material?
Ultrasonic welding principle is applied over than joining, the most application as below:
Energy ultrasonic welding: two plastic parts overlay together under pressure between which there is energy director (called welding rib) designed to melt as replacement to form joining.
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Energy ultrasonic welding: two plastic parts overlay together under pressure between which there is energy director (called welding rib) designed to melt as replacement to form joining.
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What is the advantage of ultrasonic welding?
What contents in ultrasonic system?
What is critical to ultrasonic welding?
F: Clamp Force; A: Amplitude; f: Ultrasonic Frequency
E=P*F*A*f*T
Integral form:
E = \int \mu P v \, dt, which indicates that the energy is the integral over time of the product of the friction coefficient, pressure, and velocity.
Energy density:
E = K_1 P^{n_1}, where the energy density (E) is related to the welding pressure (P) by a power function.
Energy distribution:
E_0 = E_t + E_w, where the total energy equals the sum of frictional heat generation (E_t) and heat generated by plastic deformation (E_w).
Moreover, it is very important that have suitable construction designed for ultrasonic welding according to parts material, geometric shape and welding result standard.
The types of ultrasonic welding machine
How to control the work of ultrasonic?
When stop ultrasonic output?
Depth mode:
there are two types: a. ultrasonic stops work when machine head descends to the position in height preset; b. ultrasonic stops work when machine heads descends in a moving distance preset in system.
What kind of thermoplastic material can be welded by ultrasonic?
Different material different welding result by ultrasonic, the welding compacity between two similar or two dissimilar material is different.
| Ultrasonic Welding Performance Analysis for Thermoplastic Materials | ||||
| Material Combination | Welding Compatibility | Welding Difficulty | Weld Strength (vs. Base Material) | Welding Appearance |
| ABS + ABS | Excellent | Very Low | 85% – 95% | Smooth, No Flash |
| PC + PC | Excellent | Very Low | 90% – 100% | Transparent, Glossy |
| PS + PS | Excellent | Very Low | 80% – 90% | Smooth, Minimal Flash |
| PMMA + PMMA | Good | Low | 75% – 85% | Transparent, No Cracks |
| PVC + PVC | Good | Low | 70% – 80% | Smooth, Chemical Resistance Retained |
| PP + PP | Good | Medium | 65% – 75% | Slightly Rough, Visible Weld Line |
| PE + PE | Good | Medium | 60% – 70% | Slightly Rough, High Toughness |
| PA66 + PA66 | Good | Medium-High | 60% – 70% | Rough, Visible Weld Seam |
| PET + PET | Fair | High | 50% – 60% | Brittle, Easy to Crack |
| ABS + PC | Excellent | Low | 80% – 90% | Smooth, Good Adhesion |
| ABS + PS | Good | Low | 75% – 85% | Smooth, Minimal Flash |
| PC + PMMA | Good | Medium | 70% – 80% | Transparent, Good Clarity |
| ABS + PVC | Fair | Medium | 60% – 70% | Smooth, Moderate Adhesion |
| ABS + PP | Poor | High | 30% – 40% | Uneven, Easy to Delaminate |
| PC + PP | Poor | High | 25% – 35% | Brittle, Easy to Crack |
| PS + PP | Poor | High | 20% – 30% | Uneven, Low Strength |
| PA66 + PP | Very Poor | Very High | <20% | No Effective Weld |
| PET + PE | Very Poor | Very High | <15% | No Effective Weld |
Ultrasonic cutting applies vibration in microscope level in ultra-frequency, typically 20~60Khz, to case facture on material. The vibration minimizes the friction between cutting tooling & material, achieving smooth & precision cutting to material.
MP Sonic Advanced ultrasonic system is PLL design for stability of power output. MP Sonic anti-resonance ultrasonic system achieves strong ultrasonic output under high loading. System HF control is 1 to 4 designed which means one generator can control max 4 sets of welding units (means 4 PCs of converter) in the same frequency range. Communication module is equipped with system for the integration control by production equipment.
MSP-E Series ultrasonic welder is an economical type designed ultrasonic welding machine. Machine action is forced by pneumatic cylinder meet requirement in precision and welding performance. Machine is designed wit time mode, energy mode, for different welding requirement.
MSP-G Series ultrasonic welder is a portable ultrasonic plastic welding machine designed in a lightweight for easy shifting, taking up small space. The machine applies IGBT ultrasonic system in 35KHz 1200W, or 40KHz 1000W with adjustable amplitude for different requirement. An ultrasonic handgun can be applied for ultrasonic spot welding, ultrasonic plastic stacking / riveting and ultrasonic cutting. It provides L-type and I-type welding head handle for different operation requirement and habit.
MSP-G Series ultrasonic welder Ultrasonic handgun system mostly applied for assembly production of dashboard, inner door panel, engine cover, soundproof welding of automotive, etc.
