For ultrasonic welding companies seeking a reliable and cost-effective way to bond plastic parts, ultrasonic welding has proven itself. This process can be used to join medium-sized components as well as delicate ones, such as headlight housings and car bumpers. It can also be used to weld dissimilar materials, including metals to plastics like copper and aluminum, due to the low distortion it causes. It’s important to decide whether the welding method is right for your application, however, as it’s not appropriate for all products or all materials.

Exploring the Cutting-Edge: Top Ultrasonic Welding Companies Redefining Industry Standards

The most common problem encountered with an ultrasonic welder is non-uniform joint welds. This can be caused by a number of factors. For example, the part may have been improperly cleaned, leaving behind mold release or moisture that can reduce the efficacy of the weld. The parts may not have been properly aligned during setup, and the fixture on which the welder rests isn’t providing sufficient support. Another cause is excessive filler accumulation, which results in more joint welds in some areas than others. Finally, the horn and/or booster aren’t producing a uniform amplitude.

Lastly, the welding process can be impacted by variations in the molecular structure of polymers. Amorphous thermoplastics have a gradual softening process, while semi-crystalline ones have a sharp melting point. This difference in molecular structure can impact how they absorb vibrational energy and their welding ability. In general, thinner thermoplastics are easier to weld than thicker ones.