Ultrasonic metal welding developed during the 1950s through the 1990s as the electronics used in the equipment became more sophisticated and computers could control the process. The welding can easily be automated, making clean and precise joints; the site of the weld is very clean and rarely requires any touch-up work. [17] Also, operators should be provided with hearing protection and safety glasses. Items like hospital gowns, sterile garments, masks, transdermal patches and textiles for clean rooms can be sealed and sewn using ultrasonic welding. Panel doors, housing covers and protective guards may need to be removed for maintenance. Also, high-powered welders with frequencies of 15 kHz and 20 kHz typically emit a potentially damaging high-pitched squeal in the range of human hearing. Grewell, David A.; Benatar, Avraham; & Park, Joon B. [5] Wire harnesses are large groupings of wires used to distribute electrical signals and power. Electric motors, field coils, transformers and capacitors may also be assembled with ultrasonic welding. Ultrasonic welding machines require routine maintenance and inspection. Booster: Modifies the amplitude of the vibration mechanically. This is the main obstacle in the welding of metals. The main components of an ultrasonic welding system are the actuator and power supply, converter/booster & ultrasonic horn called the stack, part holding weld fixture/jig. Ultrasonics can also be used to weld metals, but are typically limited to small welds of thin, malleable metals, e.g. These include many parts made of thermoplastic materials for interior and exterior applications, and engine compartments, but also of nonferrous metals for cable harnesses and lithium-ion batteries: For medium size metal welding specimens, (3) complex vibration welding tips have been shown to be very effective, and one-dimensional complex vibration systems are developed to simplify the systems. Handpistol 35Khz Ultrasonic Spot Welder for Welding Riveting of Film Fabric Thermoplastic Products . However, it is one of the easier materials to weld using ultrasonic welding because it is a softer metal and thus a solid-state weld is simple to achieve. The ultrasonic energy melts the point contact between the parts, creating a joint. • Ultrasonic vibrations can chip metal particulates and flakes off of inserts. The longitudinal and torsional methods produce very different welds. Longitudinal vibrations in frequencies of 20 kHz, 30 kHz, and 35 kHz with tool amplitudes between 5 µm and 50 µm are introduced into the plastic materials under the action of force. Whatever your ultrasonic plastic welding challenge is, we can solve it with a customized solution for your business. Ultrasonic welding continues to be a rapidly developing field. [11] Since aluminum is so widely used in the aerospace industry, it follows that ultrasonic welding is an important manufacturing process. [8] It is also used for bonding wiring and ribbons as well as entire chips to microcircuits. These items tend to require hermetic sealing, but cannot be subjected to high temperatures. The first application of this new technology was in the toy industry.[3]. When creating battery and fuel cell components, thin gauge copper, nickel and aluminium connections, foil layers and metal meshes are often ultrasonically welded together. [6] It is also often preferred in the assembly of storage media such as flash drives and computer disks because of the high volumes required. The parts are sandwiched between a fixed shaped nest (anvil) and a sonotrode (horn) connected to a transducer, and a ~20 kHz low-amplitude acoustic vibration is emitted. Milk and juice containers are examples of products often sealed using ultrasonic welding. Tres, Paul A., "Designing Plastic Parts for Assembly", 6th ed., 2006, This page was last edited on 13 November 2020, at 14:32. The paper parts to be sealed are coated with plastic, generally polypropylene or polyethylene, and then welded together to create an airtight seal. Description: The hand-held ultrasonic spot welder can be used for the welding, riveting, spot welding of the film, fabric, thermoplastic products and the inlaying and blanking process between the metal parts and the plastic parts. Ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. The benefits of ultrasonic welding are that it is much faster than conventional adhesives or solvents. Second, ultrasonic metal welding creates the weld via a frictional action of the surfaces that creates a solid-state bond without any melting of the material. Components joined by ultrasonics provide high strength and excellent electrical conductivity, since the vibrations destroy oxide layers and remove impurities on the metal surfaces. It offers many advantages, including process reliability and repeatability, lower energy usage than other joining techniques, material savings (because there is no need for consumables, such as glue or mechanical fasteners), and labor savings. For example, if over-welding occurs, then the concentration of plastic in the weld zone may be too low and cause the seal to break. Ultrasonic welding is a very popula… The first car made entirely out of plastic was assembled using ultrasonic welding in 1969. This container weld must be able to withstand high pressure and stress and must be airtight to contain the butane. Ultrasonic energy can weld through contaminates to create a clean seal while providing increased quality and control. An example of where microcircuits are used is in medical sensors used to monitor the human heart in bypass patients. When welding plastics, the interface of the two parts is specially designed to concentrate the melting process. Ultrasonic plastic welding is based on melting and fusion of the material (in a sense, like many metal … Contact Us. First, the depths of the welds are less than a millimeter, so the process works best on thin materials like plastics, wires or thin sheets of metal. Bonding systems of 60 to 600 kHz have been designed. Welding of plastics using ultrasonics. [1], Practical application of ultrasonic welding for rigid plastics was completed in the 1960s. Ultrasonic welding is mainly suitable for copper and aluminum connections. Ultrasonic plastic welding is suitable for virtually all thermoplastics. It has been used in the bonding of the popular composite material carbon fiber. This type of welding is often used to build assemblies that are too small, too complex, or too delicate for more common welding techniques. Ultrasonic plastic welding delivers vibrations to the zone via longitudinal vibrations that are normal (i.e., at right angles) to the weld surfaces. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. Ultrasonic welding is also applied in the packaging of dangerous materials, such as explosives, fireworks and other reactive chemicals. DONG HO Ultrasonic Plastic Welder Series of Solutions. It is commonly used for plastics and metals, and especially for joining dissimilar materials. HONGJIN SONIC is a original manufacturer of ultrasonic welding machine, ultrasonic spot welder, metal welding machine, mask making machine, geocell production line, geogrid welding machine, etc. Ultrasonic welding can be used for both hard and soft plastics, such as semicrystalline plastics, and metals. The torsional method of ultrasonically welding wire to metal parts is called Soniqtwist and was introduced in 2002 by Telsonic AG Switzerland. cell phones, consumer electronics, disposable medical tools, toys, etc.) Ultrasonic Welding Ultrasonic Welding is a plastics welding process, in which two work pieces are bonded as a result of a pressure exerted to the welded parts combined with application of high frequency acoustic vibration (ultrasonic). ... Ultrasonic Plastic Welding Tool Series. Fortunately, the risk of this kind of damage occurring is lowered when completed by experienced professionals. New ultrasonic welding methods of metal and plastic materials have been proposed by the author and have shown their effectiveness. Items such as arterial filters, anesthesia filters, blood filters, IV catheters, dialysis tubes, pipettes, cardiometry reservoirs, blood/gas filters, face masks and IV spike/filters can all be made using ultrasonic welding. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. Scientists from the Institute of Materials Science and Engineering (WKK) of University of Kaiserslautern, with the support from the German Research Foundation (Deutsche Forschungsgemeinschaft), have succeeded in proving that using ultrasonic welding processes can lead to highly durable bonds between light metals and carbon-fiber-reinforced polymer (CFRP) sheets.[4]. [15] This prevents contamination and dust production and reduces the risk of infection. The process of ultrasonic welding … [2] Soloff, the founder of Sonics & Materials Inc., was a lab manager at Branson Instruments where thin plastic films were welded into bags and tubes using ultrasonic probes. Telsonic takes an innovative path to new solutions in Ultrasonic Metal Welding. [8] One example is a butane lighter. When applied to metals, a notable characteristic of this method is that the temperature stays well below the melting point of the involved materials thus preventing any unwanted properties which may arise from high temperature exposure of the materials. We use cookies to help provide and enhance our service and tailor content and ads. [5] This process is ideal for microcircuits since it creates reliable bonds without introducing impurities or thermal distortion into components. He realized that the probe did not need to be manually moved around the part but that the ultrasonic energy could travel through and around rigid plastics and weld an entire joint. Metal Welding. However, wires, microcircuit connections, sheet metal, foils, ribbons and meshes are often joined using ultrasonic welding. With advanced testing machines and a number of senior R & D personnel with more than 20 years experience, they are committed to the research and development of various high-precision ultrasonic equipment. Ultrasonic welding can be used to bond the metal in less time and at lower temperatures than traditional welding. He unintentionally moved the probe close to a plastic tape dispenser and the halves of the dispenser welded together. … hot gas plastic welding. This is the main obstacle in the welding of metals. At this point only hard plastics could be welded. Ultrasonics would not be used in welding the chassis of an automobile or in welding pieces of a bicycle together, due to the power levels required. ScienceDirect ® is a registered trademark of Elsevier B.V. ScienceDirect ® is a registered trademark of Elsevier B.V. New methods of ultrasonic welding of metal and plastic materials. Whether two items can be ultrasonically welded is determined by their thickness. Our High Powered systems and unique Torsional Welding SONIQTWIST®, expand the metal welding spectrum, facilitating the joining of a wide range of materials, sizes and geometries previously outside the capability of Ultrasonic Metal Welding. "Port Sealing: An Effective Heat Sealing Solution". It is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. Copyright © 1996 Published by Elsevier B.V. https://doi.org/10.1016/0041-624X(96)81780-X. [17] This should be done when the power to the equipment is off and only by the trained professional servicing the machine. Ultrasonic welding is well suited for a large number of automotive components, where high part counts and appropriate strength are required. The invention of more sophisticated and inexpensive equipment and increased demand for plastic and electronic components has led to a growing knowledge of the fundamental process. The drying time is very quick, and the pieces do not need to remain in a fixture for long periods of time waiting for the joint to dry or cure. [16] The main obstacle to overcome in this process is the setting of the parameters. Figure 1depicts the two main types of systems used for ultrasonic metal welding and also show… For welding of thick and large metal specimens, (1) an ultrasonic butt welding method of joining thick metal specimens end to end is proposed. Ultrasonic welding is a very popular technique for bonding thermoplastics. Semiconductor devices, transistors and diodes are often connected by thin aluminum and gold wires using ultrasonic welding. For automobiles, ultrasonic welding tends to be used to assemble large plastic and electrical components such as instrument panels, door panels, lamps, air ducts, steering wheels, upholstery and engine components. The motion deforms, shears, and flattens local surface asperities, dispersing interface oxides and contaminants, to bring metal-to-metal contact and bonding between the surfaces.1, 2The process is solid-state, which means it occurs without melting or fusion of the base metals. One difference between ultrasonic welding and traditional welding is the ability of ultrasonic welding to join dissimilar materials. A controller controlling the movement of the press and the delivery of the ultrasonic energy. [9], Ultrasonic welding is generally utilized in the aerospace industry when joining thin sheet gauge metals and other lightweight materials. Copyright © 2021 Elsevier B.V. or its licensors or contributors. Longitudinal vibrations in frequencies of 20 kHz, 30 kHz, and 35 kHz with tool amplitudes between 5 µm and 50 µm are introduced into the plastic materials under the action of force. Operators should be informed of government agency regulations for the ultrasonic welding equipment and these regulations should be enforced.[18]. If they are too thick this process will not join them. It is also used in standard systems to clamp the stack in the press. The patent for the ultrasonic method for welding rigid thermoplastic parts was awarded to Robert Soloff and Seymour Linsley in 1965. The food industry finds ultrasonic welding preferable to traditional joining techniques, because it is fast, sanitary and can produce hermetic seals. If they are too thick this process will not join them. [3] However, many aspects of ultrasonic welding still require more study, such as relating weld quality to process parameters. [3] It is now used for a multitude of applications. All ultrasonic welding systems are composed of the same basic elements: The applications of ultrasonic welding are extensive and are found in many industries including electrical and computer, automotive and aerospace, medical, and packaging. KM-20KHz Super 3.0 “KM-Super Series” Ultrasonic Metal Welder has the most rapid progress of industrialization industry metal welding applications, especially secondary batteries, lithium-ion battery in a production sector is considered as the best option. Junctions of wire harnesses are often joined using ultrasonic welding. but it can be used on parts as large as a small automotive instrument cluster. Metal with a thin section can also be welded with USW. For joining complex injection molded thermoplastic parts, ultrasonic welding equipment can be easily customized to fit the exact specifications of the parts being welded. In addition to welding, ultrasonic energy is commonly used for processes such as inserting metal parts into plastic or reforming thermoplastic parts to mechanically fasten components made from dissimilar materials. Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. (Note: Common frequencies used in ultrasonic welding of thermoplastics are 15 kHz, 20 kHz, 30 kHz, 35 kHz, 40 kHz and 70 kHz). Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. 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