Ultrasonic welding

Підготувала
Студента групи МХ-304
Грицюк Руслана
 What are ultrasonics?
Ultrasonics are an example of the fact that
humans cannot hear every type of sound. High-
frequency sound waves are used in industry and
medicine, and these cannot be heard.
Sound waves are categorized by their frequency).
For example, ultrasonics range from 20 kHz to 1
GHz. Ultrasonic welding uses frequencies from
20 kHz to 70 kHz. The lowest range of this can
still just be heard by human ears. This is because
audible sound (for humans at least) has a range of
only from 16 Hz to 20 kHz. At most, oscillations
going above this are perceived as vibrations.
 How does ultrasonic welding
work?
When the ultrasonic vibrations hit a material, the
molecular chains start to oscillate. The molecules
start to move and rub against each other. This
generates energy (referred to as friction heat). In
the case of thermoplastic materials, this process
causes them to start to melt. Ultrasonic welding
takes advantage of this principle. After a short hold
time under additional pressure, various materials
(components) can be welded together at a
molecular level in the joining area.
What is ultrasonic welding
suitable for?
Ultrasonic welding happens in split seconds without the need for any aids
such as adhesives or screws. Ultrasonics are used to create packaging, car
parts, toys and much more, for example, by:
• Joining injection-molded parts (e.g. for toys)
• Embedding membranes (e.g. for filter membranes in medical components)
• Fusing leather, nonwovens and textiles (e.g. air filters in cars)
• Staking different types of materials together (e.g. for airbags)
• Creating form-fit joints using a shaping technique (e.g. for magnet
contacts in chargers)
• Countersinking sockets and magnets (e.g. encapsulated magnets for
activating sensors)
The ultrasonic welding system
The complete ultrasonic welding system
consists of various components. The active
components generate the vibrations, transfer
them, and apply them into the weld joints.
The passive components absorb the
resulting forces, hold the parts in position,
and particularly support the weld joint point
at which the components are joined
together.
The most important process parameters
for ultrasonic welding
Tight, sturdy and visually appealing –
to create the perfect weld joint, the
weld tool, material, and weld process
must be coordinated with each other.
Die The settings are key: The right
process parameters ensure optimal and
reproducible results.