Ultrasonic welding process uses , advantages and disadvantages
Ultrasonic welding is the clean , fast and reliable method of joining plastics , It is the use of ultrasonic frequency mechanical vibration energy ( It can be more than 15 KHZ ) in the work-piece surface to produce the plastic deformation and failure under the pressure surface , realize the welding method .
Ultrasonic welding process is most commonly used to join the thermoplastics , It is used in joining the materials which are not similar and it does not require any bolts , soldering material , nails or the adhesives that are needed to join the materials together .
Ultrasonic welding is the method of joining two parts by converting the electrical energy into the heat energy , It is suitable for the plastics and the metals , It can use high-frequency ultrasonic acoustic vibrations to the materials that are being held together under the pressure to create the solid-state weld .
Ultrasonic welding advantages
Ultrasonic welding can be applied to a diversity of combination of the material welding , It can not applied for semiconductor materials such as high temperature caused by the pollution and the operation , It is easy to weld the heat conductivity and high conductivity materials like gold , silver , copper , aluminum , etc .
The consumption power is small , only for the resistance spot welding 5% left and right sides , weld deformation less than 3-5% , solder joint strength and strength the stability by an average of about 15-20% , on the surface of cleanliness requirements is not high .
Ultrasonic welding process is widely used in the microelectronics devices and finishing technology , the most successful application is the integrated circuit element of interconnection and it is used in the electronic aerospace electrical packaging plastic industries .
Ultrasonic welding process welds thin to thick material combinations , It is excellent for Al , Cu and the other high-thermal-conductivity materials that are difficult to join by fusion processes , It can be used to join the wires and circuitry , So , It is perfect for use in the industries which produce the computer and electrical components .
Ultrasonic welding process successfully joins many dissimilar-materials combinations , It welds without filler metals or gases , It is fast and easily automated , Because ultrasonic welding does not require the connective bolts or soldering materials to bind two pieces together , it saves on the manufacturing & production costs .
The ultrasonic welding is visually appealing since there are no visible seams that can detract from the finished piece , The ultrasonic welding process is the automated process which only requires the welder to pull the lever or push the button to produce the ultrasonic weld .
Ultrasonic welding process is ideal because it creates the reliable bonds without introducing any impurities or thermal distortion to the components being joined , The ultrasonic weld dries rapidly because there are no adhesives or solvents to dry and there is no need for the materials to cure .
Although ultrasonic welding process uses the vibration to create the weld , ultrasonic welding is different method from “vibration welding” ( also known as the friction welding ) , The acoustic energy creates the friction , It produces the heat and the parts are welded in less than a second , making it one of the fastest welding methods in use today .
In the vibration welding one material is held in the place , while the other is moved back and forth by either the alternating electromagnetic or the hydraulic linear motion generator , In ultrasonic welding , both materials are held in the place and a high frequency noise is applied to produce the friction and then create the weld .
Ultrasonic Welding process offers the clean exteriors of welded parts , The potential manpower savings , The absence of drying time in the jig , the gas tight and it has completely stable , possibility of welding in the presence of the foreign bodies such as the powders and the liquids that are incompatible using any other conventional assembly processes .
Ultrasonic welding technology disadvantages
The metal ultrasonic welding requires the power with the workpiece thickness and the hardness increases exponentially , and it is limited to the silk , foil , tablet , bars such as with thin pieces of welding , most cases only applies to the lap joint .
Ultrasonic welding process is restricted to the lap joints , It is limited in joint thickness , Challenging on high-strength , high-hardness materials , The subject to the material deformation under the tooling , It may create audible noise from part resonance and the process is unfamiliar to many engineers .
The largest piece it can effectively weld is 250 mm due to the limitations in the power output capability of the single transducer , the horns inability to transmit very high power and amplitude control difficulties due to the fact that the joints of this length are comparable to the wavelength of the ultrasound .
Ultrasonic welding process requires a lower moisture content in the materials that it welds , Vibration welding is preferable for the materials with a higher moisture content , if the materials are too thick , ultrasonic welding process is not an effective way to join them .