Ultrasonic Welding - Technology Leader in Welding
Introduction:
Ultrasonic Welding is the technique in which two pieces of plastic are joined together through the use of high-frequency ultrasonic vibrations. During this process, plastics are well melted by means of ultrasonic vibrations so that a cohesive or form-fit joint is created. As an economic production method with short cycle times, Ultrasonic Welding makes certain a large degree of process control and repeatable quality results. Parts that have been welded do not require to be left in a jig for curing, which make them immediately use-able in an automation line.
Process Variations In Ultrasonic Welding:
Spot Welding - Spot welding is the process of Ultrasonic Welding of overlapping pieces of metal at small points by application of pressure and electric current. This Ultrasonic Welding is notable for the assembly of sheet steel vehicle bodies. The term "spot welding" is similarly used in the laser welding process to describe the spot welds produced by single pulses of laser light.
Resistance seam Welding - Resistance Seam Ultrasonic Welding process is very much similar to the Spot Welding but here circular rotating electrodes are used. In addition to that here we get continuous weld which is air-tight. In resistance seam welding, the Ultrasonic Welding electrodes are motor driven wheels in contrast to stationary rods. The Overlap is less than spot welding. Seam welds can be simulated by creating a spot weld joint with closely-spaced spot welds.
Micro Welding - Micro-welding in Ultrasonic Welding is a set of different technologies and equipment types which have in common the unique specialty of being able to perform welding on thin or delicate materials. This Ultrasonic Welding processes are designed to maintain tight operational tolerances while not interfering with product function and quality.
Laser Beam Ultrasonic Welding - Laser beam Ultrasonic Welding is a method in Ultrasonic Welding whereby two or more pieces of metals are joined by together through use of a laser beam. The laser beam Ultrasonic Welding is primarily used for joining components which need to be joined with high welding speeds, thin and small weld seams and low thermal distortion. The high welding speeds, automatic operation and the ability to control the quality online during the process of Ultrasonic Welding make the laser welding a general joining method in this modern industrial production. Diverse sheet thicknesses and qualities are changed into tailored blanks by welding and resistance spot welding is replaced by laser seams.
The Phases Of Ultrasonic Welding:
Start phase - The energy direction encoder melting
Fusion phase - Further heat resource leads to additional melting and a full bonding of the top and bottom components happen.
Holding phase - The work piece is held in required position and cooled under pressure during which the sonotrode yields slightly in Ultrasonic Welding.
Conclusion:
Ultrasonic Welding delivers the advantages of three-dimensional bonding that can be implemented in short welding cycles. As no adhesives are required, Ultrasonic Welding is an environment-friendly. This makes a sorted recycling achievable. This Welding is used by various industries like automotive, medical, toy and many other manufacturers where they use plastic for their product material.