Technical Information
PW-6
Ultrasonic Welding
Ultrasonic Staking
In manufacturing products with
thermoplastic components, it is often
necessary to join a thermoplastic to
a part of dissimilar material, whether
it be metal, a dissimilar plastic, or
other material. This technical informa-
tion sheet provides design guidelines,
configurations, and techniques for
successful ultrasonic staking.
General Description
Ultrasonic staking is an assembly
method that uses the controlled melting
and reforming of a plastic stud or boss to
capture or lock another component of
an assembly in place. The plastic stud
protrudes through a hole in the compo-
nent to be locked in place. High fre-
quency ultrasonic vibrations from the
horn are imparted to the top of the stud,
which melts and fills the volume of the
horn cavity to produce a head, locking
the component in place. The progressive
melting of plastic under continuous but
generally light pressure forms the head.
The advantages of ultrasonic staking
include:
• S hort cycle time (generally less than
one second).
•T
 ight assemblies with virtually no
tendency for recovery (memory).
•M
 inimal stress in the formed plastic.
•T
 he elimination of consumables such
as screws and rivets.
•T
 he ability to perform multiple stakes
with one horn.
•R
 epeatability and control over the
process (consistent results).
•D
 esign simplicity.
Staking Considerations
In order to design the part correctly,
a number of questions must first be
answered:
1. What material is being used?
2. What strength will be required?
3. What loading must the stake resist
in normal use (e.g., tensile, shear)?
4. Is appearance important?
5. Will multiple stakes be necessary?
If so, what is the distance between
the studs?
6. Are the stakes recessed in the part
and, if so, is there clearance for
the horn?
 lines, configurations, and techniques for successful being staked that determine the type of design to be
ultrasonic staking. tip is less
utilized.
file tip w
General Description Staking Configurations Knurled
2D
Ultrasonic staking is an assembly method that uses available
The integrity of an1.6D
ultrasonically staked assembly
the controlled melting and reforming of a plastic
0.5D designed
depends upon the volumetric relationship between
tip isisless
and us
stud or boss to capture or lock another component the stud and horn cavity and the ultrasonic para-
file tip wT
critical.
of an assembly in place. The plastic stud protrudes meters used when forming the stud (e.g., amplitude
Figure multiple
Knurled
through a hole in the component to be locked in of the2.horn,
Standard
weldprofile
time, stake
pressure). (See
2D
Figure 1.)
place. High frequency ultrasonic activity from the precise
availablea
horn cavity. The head produced is twice the 0.5D
1.6D diam- welding
designed
horn is imparted to the top of the stud, which melts
These questions must be and fills the volume
the molded stud is flat, and eter of the stud and satisfies the requirements of
of the horn cavity tomelt is a
produce and is us
answered to determine thehead, locking initiated by the small, the majority of staking applications. It isD/2 radius
ideal for
the component in extended
place. The pro- critical. T
requirements of the application, staking non-abrasive (unfilled) thermoplastics, multiple
pointof
gressive melting in the hornunder
plastic cavity.continuous
The head but Figure 2. Standard profile stake
both rigid and non-rigid. Standardized threaded precise a
for it is these requirements generally light pressure forms the head.
produced is twice the diameter of horn
horn tips forThe
cavity.
Radius tapped
headhorns
produced are available
is twice the for diam-
studs welding
and the physical size of the The
stud(s)
advantages
the of ultrasonic
stud staking
and satisfies theinclude:
require- with ofdiameters
eter(typical) the studofand 1/32 to 3/16
satisfies
D the inch (0.8
requirements
1.6D
to 4.8
of
being staked that determine the
• Short cyclementstime
of the(generally
majority ofless
staking
than one mm). The standard profile should notIt be used for
the majority of staking applications. is ideal for
type of design to be utilized. second) applications. It is ideal for staking studs
stakingmore than 5/32 (unfilled)
non-abrasive inch (4 mm) in diameter.
thermoplastics,
• Tight assemblies with (unfilled)
virtually no tendency for Low
both profile
rigid and or hollow
non-rigid.staking should be used.
Standardized threaded For
Staking Configurations non-abrasive thermoplas-
recovery (memory) studs
horn tips less than 1/8 inch,
for tapped hornsthe are
dome stake (described
available for studs Figure 5.
tics, both rigid and non-rigid. below) should beofused. D = Stud diameter
The integrity of an ultrasonically
• Minimal stress in the formed plastic with diameters 1/32 to 3/16 inch (0.8 to 4.8
staked assembly depends upon Standardized threaded horn tips mm). The standard profile
• The elimination of consumables such as screws Low
Figure
Figure Profile
1. Stake —
Relationship
1. Relationship Low should
between
between profile
stud
studandnot be
staking
andhornhornused
(Figure
cavity for
cavity Flush St
the volumetric relationship and rivets.for tapped horns are available for studs more than 5/32 inch (4 mm)
3) is very similar to standard profile staking. It dif- in diameter. surface a
between the stud and horn•cavity studs
The ability with diameters
to perform multipleofstakes
1/32 to
with one Low
fers inprofile
the heightor hollow
of thestaking
finished should
stakedbehead.used.This For tained
tip is less p
Proper
studs less stake
than design
1/8 inch, produces
the dome optimum
stake strength
(described
and the ultrasonic parameters horn 3/16 inch (0.8 to 4.8 mm). The reduction of head height (low profile) is advanta- Figure
file tip5.w6
(Figure
and appearance
below)
geous inshould bewith
applications used. minimal or no flash.
where space is limited, and it domeTecst
used when forming the stud• (e.g., standard
Repeatability profile should
and control over thenot be (con-
process Knurled
Several
improves
Low Profile configurations
cycle times;
Stake for profile
—however,
Low stud/cavity 2D design
it produces
staking lowerare
a(Figure horn orSt
sistent results)
amplitude of the horn, weld time, used for studs more than 5/32 inch Flush
available
available.
strength
3) is verystake. The principle
1.6D
similar to standard of staking is the
profile staking. It same dif-for for all tha
pressure – see Figure 1). • Design simplicity 0.5D surface
designed
(4 mm) in diameter; low profile each: The area of initial contact between the horn
fers in the height of the finished staked head. This tained
and is us p
or hollow staking should be used. and stud should be kept to a minimum. This allows
Staking
Proper stud design produces opti- Considerations reduction of head height (low profile) is advanta-
a concentration of the mechanical vibrations
(Figure
critical. 6T
mum strength and appearance For studs less than 1/8 inch, the
In order to design the part correctly, a number of geous in applications where space is limited, andinit a dome
multiple st
Figure
localized 2. Standard
area to profile stake
create a rapid melt, which speeds
dome stake (described below) Figure
improves 2. Standard
cycle times;profile stake it produces
however, 1.5D a lower horn
preciseor a
with minimal or no flash. questions must first be answered: up the cycle on the part. This is true with each of
shouldisbe used.used? strength
horn cavity. stake.The head 0.6D produced is twice the 0.25D diam- for allfaxth
welding
1. What material being the following designs, as well as customized designs
Several configurations for stud/ eter of the stud and satisfies the requirements of em
Low Profile
2. What strength will be Stake — Low profile
required? to meet a specific part requirement.
cavity design are available. The the majority of staking applications. It is ideal for son
3. What loading must the stake resist
staking (Figure 3) is very in normal
similar to Standard
staking Profile Stake
non-abrasive — The thermoplastics,
(unfilled) standard profile
principle of staking is the sameuse
for(e.g., tensile, shear)? Figure
stake 3. Low
(Figure profile
2) is stake
most
both rigid and non-rigid. Standardized commonly usedthreaded
for studs
standard profile staking. It differs 1.5D
each: the area of initial contact
4. Is appearance important? having a diameter
horn tips for tapped0.6D between 1/8 and 5/32
horns are available for0.25D inch studs(3.2 Figure 6.
in the height of the finished staked
between the horn and stud5. should
Will multiple staking be necessary? If so, what to
Dome 4 mm). The
Stake —of
with diameters top
The of
dome
1/32 the molded
stake (Figure
to 3/16 stud
inch (0.8 is flat,
4) tois rec-and
4.8
head. This reduction of head height melt is initiated by the small, extended point in the
be kept to a minimum. This allowsis the distance between the studs? ommended
mm). The standard for studsprofilewith ashoulddiameter not of be 1/8
usedinch for Hollow
(low profile) is advantageous in (3.2
studsmm) moreor than less, or where
5/32 inch multiple
(4 mm) studs are being
in diameter. generally
a concentration of the mechanical applications where space is limited, Figure
staked.
Low 3. 3.Low
ItLow
profile orprofile
is profile
especially
hollow stake
useful
stakingforshouldvery smallbe used.diame- For
Figure stake than 3/1
vibrations in a localized area to and it improves cycle times; however, ters,
studsorless when thanthe 1/8material
inch, the is glass-
domeorstake mineral-filled.
(described Figure 6.
Figure of
studs 5.
create a rapid melt, which speeds it produces a lower strength stake. below) Stake
Dome should— beThe
used. dome stake (Figure 4) is rec- prevent
up the cycle on the part. This is ommended
Low Profile Stake —with
for studs Lowaprofilediameter of 1/8
staking inch
(Figure hollow
Hollow
Flush St s
Dome Stake —The dome stake having
true with each of the following (3.2 mm) or less, or where multiple
3) is very similar to standard profile staking. It dif- studs are being surface at
generally
(Figure 4) is recommended for studs 0.5D It is especially useful for very small diame-
staked. material.
than
fers in the height of the finished staked head. This tained3/1p
designs, as well as customized with a diameter of 1/8 inch (3.2 mm) ters, or when
reduction of the
headmaterial
2.1D is
height glass-
(low or mineral-filled.
profile) is advanta- studs
(Figureof6
designs to meet a specific part or less, or where multiple studs are geous in applications where space is limited, and it prevent
dome st
requirement. being staked. It is especially useful improves cycle times; however, it produces a lower hollow
horn ors
strength stake. having
for all tht
Standard Profile Stake — for very small diameters, or when the
0.5D
Figure material.
The standard profile stake (Figure 2) material is glass or mineral filled. Figure 4.4.Dome
Domestake
stake
2.1D
is most commonly used for studs The top of the stud should be tapered The top of the stud should be tapered (cone-
having a diameter between 1/8 and
shaped), the point of which initiates material melt,
(cone-shaped). This helps initiate
reducing energy being transmitted1.5D through the
5/32 inch (3.2 to 4 mm). The top of melting while reducing energy being 0.6D 0.25D Figure 7.
stud. Alignment between the horn and the stud is
Figure 4. Dome stake
not as critical as with the standard profile, because
the
Thetiptopandofpart
the will
studself-align.
should be Thetapered
dome staking
(cone-
shaped), the point of which
Figure 3. Low profile stake initiates material melt,
reducing energy being transmitted through the Figure 6.
stud. Figure 7.
DomeAlignment
Stake — The between
dome thestake
horn(Figure
and the4)stud is
is rec-
not as critical as with the standard profile,
ommended for studs with a diameter of 1/8 inch because
Hollow
the
(3.2tip
mm) andorpart
less, will self-align.
or where Thestuds
multiple domearestaking
being generally
 Figure The
mm). 2. Standard
standardprofile profile stakeshould not be used for tip is lessalignment
susceptibleortostud weardiameter.
than the standard pro-
studs more than 5/32 inch (4 mm) in diameter. precise A hand-held
horn cavity. The head produced is twice the diam- file tip when glass-filled
welding tool may be utilized. materials are being staked.
Low profile or hollow staking should be used. For
eter of the stud and satisfies the requirements of Knurled Stake — The knurled stake (Figure 5),
studs less than 1/8 inch, the dome stake (described Figure 5. Knurled stake
the majority of staking applications. 2D It is ideal for available in both male and female patterns, is
below) should be used. 1.6D
staking non-abrasive (unfilled) thermoplastics, 0.5D designed for simplicity and rapid rate of assembly,
Low
both Profile
rigid and Stake — Low Standardized
non-rigid. profile stakingthreaded (Figure Flush
and is Stakeused when — For applications
appearance andrequiring
strength aareflushnot
3)
horn is very
tips similar
for tapped to standard
horns are profile staking.
available forItstuds
dif- surface
critical. There is no dimensioned hornincavity,
and having sufficient thickness the con-
and
fers
withindiameters
the heightofof1/32 the finished
to 3/16staked inch (0.8 head.toThis 4.8 tainedmultiple piece
stakes to may
allowbeformade a recess,
without the concern
flush stake for
Figure 2. Standard
reduction
mm). Theofstandard head profile
height stake
profile(low should profile)
not be is advanta-
used for (Figure 6) is ideal. The tapered
precise alignment or stud diameter. A hand-held stud design used for
Also, where geous horn
studs in
disassembly
cavity.
more applications
for head
The
than repair
5/32 whereis aspace
produced
inch (4 isistwice
primary
mm) limited, The
in the and
diam-
diameter. it stud
plastic dome
welding staking
melts intomay
tool is
therecommended,
cavity
be of the horn.
utilized. and a flat-faced
requirement of improves
eter
Low theof the
profile cycle
application,or times;
stud repairs
and
hollow however,
can bethe
satisfies
staking itmade
produces
should requirementsAahold
be used. lower horn
(dwell)
of
For timeoristip then is utilized.
required Flush to allow staking
solid-may be used
transmitted through the stud. strength
Align- having to melt and displace toIt ais(described
large
by removing the
studs lessstake.
the majority
formed than stud
of head
staking
1/8 inch, for access
applications.
the dome stake ideal for of for
ification theallreformed
Figure thermoplastics.
5. Knurledstud stakehead. Sufficient
ment between the horn and
internal the
componentsstud should
staking
below) andvolume driving
non-abrasive
be used.of material.
a(unfilled)
self-tapping clamp force between the formed head and the horn
thermoplastics,
is not as critical asscrew
with theintostandard
the
both inside
Low Profilerigid diameter
andStake
Also,
of the Standardized
non-rigid.
where— Low
stud for
profile staking
disassembly for repair
during
threaded
(Figure
solidification will keep the parts tightly
reassembly. Flush Stake — For applications requiring a flush
profile, because the tip and part horn tips for tapped horns are available locked
for studs together.
3)mayis very similar to standard
is a primary requirement profile of staking.
the It dif- surface and having sufficient thickness in the con-
self-align. The dome staking tipwith indiameters
is less
fers the heightofof1/32 to 3/16 staked
the finished inch1.5D(0.8head. toThis4.8
High-Pressure Method
tained piece to allow for a recess, the flush stake
Process Parameter mm). The of Guidelines
application,
standard repairs
profile
0.6D shouldcan be notmade be used
0.25D for
susceptible to wear than the standard reduction head height (low profile) is This
advanta- (Figure
method involves 6) isreforming
ideal. Thethe tapered
plastic studstuddesign used for
When settingstuds more
up a staking
geous in bythanremoving
5/32where
application,
applications the
inch useformed
(4themm)
space fol-
is studin head
limited, diameter.
and it
profile tip when glass filled materials without dome staking is recommended, and a flat-faced
lowing standardLow
improves profile
process or access
for
cycle hollow
parameters
times; to staking
as should
a guideline:
internal
however, itcomponents
produces be used.a For reaching its melting temperature on the
lower
surface, creating horn or tip
a condition is utilized.
that Flush staking
softens and forms may be used
are being staked. studs lessstake.
than
• Slow downspeed strength and1/8 inch,a self-tapping
driving the dome stake screw(described Figure
Figure
for 5. 5.
all Knurled
Knurled
thermoplastics. stake
stake
the stud into a mushroom shape when using a flat-
Figure
below)3.should Low profilebe used.stake
Knurled Stake •— The knurledof
Pretrigger stake
low Dynamic into the insidesetting
Trigger diameter of the faced stud horn. (Cavities
Figure 6. may Flushalso stake be used.) The high-
(Figure 5), available• inLowboth maleLow
pressure and Profile Stake — Low profile staking (Figure Flush Stake — Forresilient
applications requiring a flush
Dome Stake for— reassembly.
The dome stake (Figure pressure
4) is rec- method works best with materials
3) is very similar to standard profile staking. It dif- surface and having sufficient thickness in the con-
female patterns, •is designed
Mediumfor tosim-
high amplitude
ommended for studs (refer
with toa diameter
Branson of 1/8 suchinch as ABS Hollow
and high-impact Staketo— styrene
Thefor or polyethyl-
hollow stakethe(Figure 7) is
fers in the height Process of the finished
Parameter staked head. This tained piece allow a recess, flush stake
1.5D ene and polypropylene. However, it has also been
plicity and rapid rate Amplitude
of assembly. (3.2Reference
Itmm)
reduction is or Guide,
of less,
TL-2)
headorheightwhere multiple
(low profile)studs is are being
advanta- generally
(Figure 6) used
is when
ideal. The studs
taperedare equal
stud to
design or greater
used for
0.6D
used when appearance • Rigid andsupportgeousunder
staked.
strength is Guidelines
studs
inItapplications
especially where useful space for very smallfound
is limited,
0.25D
diame- to work well3/16
and it than dome
withinch
staking
more(4.8
is
rigidmm)materials
recommended,
such
in diameter.
and a Hollow
flat-faced
ters, or when thetimes;
material is glass- as polycarbonate and acetal.
are not critical asMultiple improves
flash cannotStaking
be con- When
cycle setting up
however, it or
a staking mineral-filled.
producesapplica- a lower studs horn or offertip advantages
is utilized. Flush in molding,staking because
may be theyused
strength stake.
tion, use the following standard
The mechanics prevent
for used
all to
surfaceaccomplish
thermoplastics. sinks and high-pressure
internal voids. Staking a
trolled. There is no Indimensioned
many cases, horn
more than profile one stud may be staked
Figure 3. Low stake staking require hollow highstud force between
produces the working
a large, strong head without
cavity, and multiple in astakes
singlemay be
operation. process
The parameters
feasibility as a guideline:
of multiple face of the horn Figureand
having the
6.toFlush
melt top and
stake of the plastica stud
displace large volume of
made without concern stakingforisprecise
determined by• Sthelowability
downspeed. to design a before energizingFigure 6.the Flush stake horn, and using a
ultrasonic
0.5D material.
Dome Stake — The dome hornstake used(Figure 4) is rec-
alignment or studhorn that will
diameter. function
A hand- properly.
•for
The
 retrigger
P 2.1D of low Dynamic
for low-amplitude horn.
multiple ommended
staking can be studs
half-wavelength with a diameter
or com- 1.5D of 1/8 inch Hollow Stake — The hollow stake (Figure 7) is
held welding tool may be utilized. (3.2Ifmm) Trigger
or less, 0.6Dsetting. The0.25D horn reforms theusedstudwhen to generate a mush-
posite in design. the studs areoron where
the same multiple plane studs are
room
being
head on
generally
the top of the stud.
studs are
The travel
equal to or greater
dis-
Flush Stake — For andapplications staked.
within 1/2 inch (12.7 It is especially
• L ow mm) useful
pressure.
of each other, afor very small diame- than 3/16 inch (4.8 mm) in diameter. Hollow
ters, or when the material is glass- or tance
mineral-filled. selected can
studs permit
offer the parts
advantages joined
in to
molding,move because they
half-wave
requiring a flush surface andhorn
having is recommended. •M  stake Large parts hav-
edium to high amplitude (refer freely or be preventtightly locked together. Itinternal
is recom- 1.5D
Figure 4. Dome surface sinks and voids. Staking a
sufficient thickness inginstuds widely
the containedFigure spaced
3. Low onprofile
the same plane would
stakeAmplitude mended that hollow only low profile plastica large,
studs be usedhead without
to Branson Reference stud produces strong 0.25D
require a full-waveThe top composite
of the horn stud to shouldprovide be the taperedto (cone- help prevent Figure 6. Flush
stud stake(deflection) when
piece to allow for a recess, the flush
necessary amplitudeshaped),for Guide,
thestaking.
point of TL-2).
which initiates material melt, having tobending
melt and displace a large volume of
stake (Figure 6) is ideal. The tapered Dome
0.5D Stake — The dome stake (Figure 4) is rec- high pressure is applied
material. between the top of the stud
reducing energy •R  igidbeing
support transmitted
under studs. through horn. the
stud design usedStaking ommended for studs
Techniques
for dome staking with a diameter of and 1/8 inch Figure Hollow
Figure 8 7.
showsStake
Hollow a cross
— section
The
stake of a mush-
hollow stake (Figure 7) is
stud.isAlignment between 2.1D the horn and the stud is Figure
room-formed stud.7. Hollow stake
(3.2 mm) or less, or where multiple studs are being generally used when studs are equal to or greater
recommended, and Twoa flat-faced
methods nothornas critical
are Multiple
as with the Stakingstandard profile, because
staked. Itrecommended
is especially useful for staking,
for very small diame- than 3/16 inch (4.8 mm) in diameter. Hollow
or tip is utilized. Flush stakingupon the tip
may and part will self-align. The dome staking
depending ters,bethe material
or when In the
many andcases,
material staking require-
isseveral
glass- studs may
or mineral-filled. studs offer advantages in molding, because they
ments: theThis
used for all thermoplastics. conventionalbemethod, which is most
staked in a single operation. prevent surface sinks and internal voids. Staking a
Figureand 4. Dome stake 1.5D
frequently
stake provides less strength than used, the high-pressure method. hollow stud produces a large, strong head without
Both methods of topstaking Furthermore,
require the staking
stud be toof be
studs on 0.25D
other designs. The of the stud should tapered (cone- having to melt and displace a large volume of
properly located and multiplesupported
rigidly planes candirectly be accommo-
shaped),
0.5D the point of which initiates material melt, material.
Hollow Stake —below to ensure
The hollow stake correctenergy
reducing dated
alignment as long
being with as the theplanes
transmitted are
horn through the
2.1D
cavity, and
(Figure 7) is generally used when that energy
stud. Alignment will
relativelybe
betweenexpended
close the to one at
horn the
another
and the stud is Figure 7. Hollow stake
horn/stud interface rather
not as critical than
(typically exciting
as withless thethan the
standard entire
0.25”). The feasi-
profile, because
studs are equal to or greater than
plastic assembly the and
tip fixture.
and part will self-align. The dome Figure
staking 8. High-pressure stake
3/16 inch (4.8 mm) in diameter. bility of multiple staking is dependent Figure 8. High-pressure stake
Conventional
Hollow studs offer advantagesFigure Method
in upon
4. Dome stake the ability to design a horn 1.5D
Process parameters for the high-pressure method
molding, becauseInthey thisprevent
instance,
Thethe topintentofthat iswill
the tostudlocalize
functionshould the ultra-
properly.
be Also, the
tapered are(cone-
as follows:
0.25D

surface sinks andsonic energy

internal voids.at the topthe
shaped), of the plastic
quality
point of
of the
whichstud,
results sowill
initiatesonly be function
material
this area of the stud begins to melt. The mechanics • melt,Medium downspeed
Staking a hollow stud producesreducing energy of partbeing dimensional transmitted consistency through the
used to generate • Medium Figure to high7.Dynamic Trigger setting
a large, strong head without stud.this method of
Alignment and horn
melt staking
between amplitude the horn often and the stud is
uniformity.
Hollow stake
require pretriggering (energizing the ultrasonic
not as critical as with the standard profile, because • Medium to high pressure
horn) prior tothe contacting
tip and part the top willofself-align.
the stud.The dome• staking Low amplitude
The horn descends onto the stud at a preset speed • Rigid support under the studs.
and pressure (bearing force) to allow surface melt-
ing of the stud to occur. It is important that the
downspeed of the horn is not faster than the melt-
ing rate of the plastic stud; this prevents the stud
from being deformed or buckling.
Staking Techniques head and the horn during solidifica- •M
 edium downspeed.
Two methods are recommended tion will keep the parts tightly locked •M
 edium to high Dynamic
for staking, depending upon the together. Trigger setting.
material and staking requirements, •M
 edium to high pressure.
High-Pressure Method
the conventional method (most fre- • L ow amplitude.
quently used), and the high-pressure This method involves reforming the
plastic stud without reaching its •R
 igid support under the studs.
method. Both methods of staking
require the stud to be properly melting temperature on the surface, Other Design Guidelines
located and rigidly supported directly creating a condition that softens and
No matter which particular staking
below to ensure correct alignment forms the stud into a flat nail head Other Design Guidelines Note: The ratin
configuration is chosen, there are strength of the w
with the horn cavity, and that energy shape when using a flat-faced horn.No matter which particular staking configuration is
certain design features or character- Information She
(cavities may also be used.) The highchosen, there are certain design features or charac-
will be expended at the horn/stud
teristicsistics
thatthat
are are generic.
generic. Designing
Designing withthese in
with information.
interface rather than exciting the pressure method works best with
mind canthese in mind the
maximize caneffectiveness
maximize theand consisten- Material
entire plastic assembly and fixture. resilient materials such as ABS and cy of the process. and consistency of the
effectiveness Amorphous Po
high-impact styrene or polyethylene process.
1. A radius at the base of the stud helps to elimi-
Conventional Method ABS . . . . . .
and polypropylene. However, it has nate areas of high stress concentration, such as ABS/polycarb
In this instance, the intent is to local- 1. A radius at the base of the stud
also been found to work well with is found in sharp corners. Two ways to incorpo- Acrylic . . . . .
ize the ultrasonic energy at the top helps to eliminate areas of high Acrylic multip
more rigid materials such as polycar- rate this radius are illustrated in Figure 9.
of the plastic stud, so only this area Failurestress
to addconcentration, suchresult
this detail could as in burning Butadiene-sty
bonate and acetal.
those found
or fracturing in sharp
of the stud atcorners.
the baseTwoinstead of Phenylene-oxi
of the stud begins to melt. The
The mechanics used to accomplish dissipating ways totheincorporate
energy at this
the radius
horn/stud
are inter- Polycarbonate
mechanics used to generate this Polystyrene (g
high-pressure staking require high face. illustrated in Figure 9. Failure to
method of melt staking often require Polystyrene (r
force between the working face of Polysulfone .
pretriggering (energizing the ultra-
sonic horn) prior to contacting the the horn and the top of the plastic PVC (rigid) .
stud before energizing the ultrasonic SAN-NAS-AS
top of the stud. Xenoy (PBT/p
horn, and using a low amplitude.
The horn descends onto the stud at Semi-Crystallin
a preset speed and pressure (bearing The travel distance selected can Acetal . . . . .
force) to allow surface melting of permit the parts joined to move Cellulosics. . .
the stud to occur. It is important that freely or be tightly locked together. Liquid crystal
Figure 9. Incorporating
Figure a radiusa in
9. Incorporating stud/part
radius in design Nylon . . . . .
the downspeed of the horn is not It is recommended that only low
stud/part design Polyethylene .
faster than the melting rate of the profile plastic studs be used to help Polymethylpe
2. Part-to-part fit regarding the diameter of the
plastic stud as this prevents the stud prevent stud bending (deflection) Polyphenylene
stud and the detail
add this through-hole is critical.
could result in burn- As was
from being deformed or buckling. when high pressure is applied Polypropylene
statedingearlier,
or fracturing of the studformed
the integrity of the at the head is
between the top of the stud and Code: 1 =
The plastic stud melts into the cavity a volumetric
base instead of dissipating the the cavity
relationship between
horn. Figure 8 shows a cross section and displaced material. Variations in part-to-
of the horn. A hold (dwell) time is energy at the horn/stud interface. Ordering Info
of a mushroom- formed stud. part fit could change this relationship resulting
then required to allow solidification
in 2.Part-to-part
inconsistency. For fit between
example,the diam-
a gap along the Standard and lo
of the reformed stud head. Sufficient Process parameters for the high- walls between the stud diameter
eter of the stud and the through- and hole diam- below; other pro
clamp force between the formed pressure method are as follows: eterhole
(seeisFigure 10) could allow some
critical as the integrity of the of the dis- ing tips can be m
placed material to flow into the gap, making
less material available to form the head. It is, Identific
Letter a
therefore, recommended that the fit be as close Tip Dia. Descrip
as possible. 1/2" A std. pr
1/2" B std. pr
1/2" C std. p
1/2" D std. p
Ultrasonic
product
Welding
name 1/2"
1/2"
E std. pr
F std. pr
Branson Figure 10. Part-to-part fit
1/2"
1/2"
G low p
H low p

Figure 9. Incorporating a radius in stud/part design
SAN-NAS-ASA . . . . . . . . . . . . . . . . . 4
Xenoy (PBT/polycarbonate alloy). . . . . 4
Semi-Crystalline Polymers
Acetal . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cellulosics. . . . . . . . . . . . . . . . . . . . . . 2
Liquid crystal polymers . . . . . . . . . . . . 3
Nylon . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Part-to-part fit regarding the diameter of the

Ultrasonic Welding
Polyethylene . . . . . . . . . . . . . . . . . . . . 3
Polymethylpentene . . . . .. . . . . . . . . . . 3
Polyphenylene sulfide . . .. . . . . . . . . . . 5
stud and the through-hole is critical. As was
Polypropylene . . . . . . . . . . . . . . . . . . . 1
stated earlier, the integrity of the formed head is
formed head is dependent upon the Note: The ratings
Code: 1 = below
easiest,do5 =not relate
most to the strength of the
difficult
a volumetric relationship between the cavity
volumetric relationship between the weld obtainable. Refer to Technical Information Sheet PW-1
and displaced material. Variations in part-to-
part fitcavity
couldand displaced
change material. Varia-
this relationship resulting Ordering
for Information
detailed polymer information.
in inconsistency. For example,could
tions in part-to-part fit a gapchange
along the Standard and low profile staking tips are listed
walls between the stud diameter Material Ease of Staking
this relationship resulting and hole diam-
in inconsis- below; other profiles such as dome or hollow stak-
eter (seetency.
Figure
For10) could allow
example, a gapsome
alongofthe
the dis- Amorphous Polymers
ing tips can be made to special order.
placed walls
material to flow into the gap,
between the stud diameter and
making ABS 1
less material available to form the head. It is, Identification
hole diameter (see Figure 10) could Letter and Stud Stud
therefore, recommended that the fit be as close ABS/polycarbonate
Tip Dia. DescriptionalloyDia.
Length* EDP No. 2
allow some of the displaced material
as possible. Acrylic
1/2" A std. prof. 1/32" x 0.050" 101-148-034 4
1/2" multipolymer
Acrylic B std. prof. 1/16" x 0.100" 101-148-035 2
1/2" C std. prof. 3/32" x 0.150" 101-148-036
Butadiene-styrene 2
1/2" D std. prof. 1/8" x 0.200" 101-148-037
1/2" E std. prof.
Phenylene-oxide based 5/32"
resins x 0.250" 101-148-038 2
1/2" F std. prof. 3/16" x 0.300" 101-148-039
Polycarbonate 3
son Figure 10. Part-to-part fit
Figure 10. Part-to-part fit
1/2" G low prof. 1/32" x 0.019" 101-148-040
1/2" H low prof. 1/16" x 0.038" 101-148-041
Polyetherimide 4
dwide 1/2" I low prof. 3/32" x 0.056" 101-148-042
Polystyrene
1/2" J low (general
prof. purpose)
1/8" x 0.075" 101-148-043 4
quarters to flow into the gap, making less
1/2" K low prof.modified)
5/32" x 0.094" 101-148-044
Polystyrene (rubber 1
material available to form the head. 1/2" L low prof. 3/16" x 0.112" 101-148-045
e Road Characteristics
Therefore,of Thermoplastic
a slip fit is typically recom- Polysulfone 3
5/8" M std. prof. 7/32" x 0.350" 101-148-046
y, CT 5/8" N std. prof. 1/4" x 0.400" 101-148-047
Polymers for Staking
mended. PVC (rigid)
5/8" O low prof. 27/64" x 0.253" 101-148-048
2
961
onUltrasonics.com
The codes Characteristics
in the following table indicate relative
of Thermo- SAN-NAS-ASA 3
5/8" P low prof. 15/32" x 0.281" 101-148-049
ease of staking for the more common thermoplastic
plastic Polymers for Staking Xenoy (PBT/polycarbonate
*Stud length alloy)
is defined as the length of the stud that protrudes 3
polymers. Use the table as a guide only, since varia-
The codes above the material to be staked.
n Ultrasonics tions in resins mayin the following
produce table different
slightly
on, 1980 Semi-Crystalline Polymers
results. indicate relative ease of staking for Staking tip kit containing all the above
d Printed in
the more common thermoplastic Acetal
tips and a storage case: 101-063-027 3
6 www.Branson-PlasticsJoin.com
polymers. Use the table as a guide Cellulosics 2
only, since variations in resins may Liquid crystal polymers 4
produce slightly different results. Nylon 3
For instance, staking becomes more
Polyethylene 2
difficult when parts are filled with
Polybutylene Terephthalate (Polyester, PBT) 4
20% or more glass (or other fillers).
Polyethylene Terephthalate (Polyester, PET) 4
Polymethylpentene 3
Polyphenylene sulfide 4
Polypropylene 1

Code: 1 = easiest, 5 = most difficult

 Technical Information
PW-6

Ordering Information
Standard and low profile staking tips are listed below; other profiles such as dome or
hollow staking tips can be made to special order.

Identification Letter Stud Stud

Tip Dia. and Description Dia. Length* EDP No.
1/2” A std. prof. 1/32” x 0.050” 101-148-034
1/2” B std. prof. 1/16” x 0.100” 101-148-035
1/2” C std. prof. 3/32” x 0.150” 101-148-036
1/2” D std. prof. 1/8” x 0.200” 101-148-037
1/2” E std. prof. 5/32” x 0.250” 101-148-038
1/2” F std. prof. 3/16” x 0.300” 101-148-039
1/2” G low prof. 1/32” x 0.019” 101-148-040
1/2” H low prof. 1/16” x 0.038” 101-148-041
1/2” I low prof. 3/32” x 0.056” 101-148-042
1/2” J low prof. 1/8” x 0.075” 101-148-043
1/2” K low prof. 5/32” x 0.094” 101-148-044
1/2” L low prof. 3/16” x 0.112” 101-148-045
5/8” M std. prof. 7/32” x 0.350” 101-148-046
5/8” N std. prof. 1/4” x 0.400” 101-148-047
5/8” O low prof. 27/64” x 0.253” 101-148-048
5/8” P low prof. 15/32” x 0.281” 101-148-049

*Stud length is defined as the length of the stud that protrudes above the material to be staked.

Staking tip kit containing all the above tips and a storage case: 101-063-027

Notes bold 7.5pt

Notes 7.5pt Weoiosid wkeoijsdon csdkncwlejoic osijeofnkeoijsdon csdkn cwle joic osijeofn keoijsdon
csd kncwlejoic osijeofn keoijsdon csdkncw lejoic osijeofn keoijsdon csdkncwlejoic c osijeofnk eoijs
Branson
Address Ultrasonics
Weoiosid wkeoijsdon
Corporation don csd kncwlejoic osijeofn keoijsdon csd kncwlejoic osijeofn keoijsdon .
41
Address
Eagle Road,
Weoiosid
Danbury,
wkeoijsdon
CT 06813-1961
(203)
Address
796-0400
Weoiosid
• Fax:
wkeoijsdon
(203) 796-9838 Notes bold 7.5pt
www.bransonultrasonics.com Notes 7.5pt Weoiosid wkeoijsdon csdkncwlejoic osijeofnkeoijsdon csdkn cwle joic osijeofn keoijsdon
e-mail: info@bransonultrasonics.com csd kncwlejoic osijeofn keoijsdon csdkncw lejoic osijeofn keoijsdon csdkncwlejoic c osijeofnk eoijs
don csd kncwlejoic osijeofn keoijsdon csd kncwlejoic osijeofn keoijsdon
csd kncwlejoic osij.

ISO Certifications
PW-6 © Branson
Copyright Ultrasonics
info 6pt WeoiosidCorporation 2013
wkeoijsdon csdkncwlejoic osijeofnkeoi-
The Emerson
jsdon logojoic
csdkn cwle is aosijeofn
trademark and service
keoijsdon mark of Emerson
csd kncwlejoic osijeofn keoi-
Electric Co. Revised and printed in the U.S.A. 4/13
jsdon csdkncw lejoic osijeofn keoijsdon csdkncwlejoic c osijeofnk.