Ultrasonic Welding System

  • The parts to be welded are placed in the anvil or fixture.
  • The horn contacts the parts to be welded.
  • Pressure is applied to keep the horn in contact with the welded materials and to hold them together.
  • The horn delivers ultrasonic vibrations to heat up the materials.
  • The vibrations move less than 1mm either up/down or side-to-side.
  • The materials are welded together.
  • The horn gets retracted and the welded materials can be removed from the anvil.
AMTEC ULTRASONIC WELDING

Ultrasonic Welder – bench top model

AMTEC ULTRASONIC WELDING

Ultrasonic welding face mask

AMTEC ULTRASONIC WELDING

Compact Ultrasonic module for Integration with Automation System

AMTEC ULTRASONIC WELDING

Ultrasonic Welding threaded insert in plastic part

AMTEC ULTRASONIC WELDING

Ultrasonic Welding for Semi-Automated system

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Advantages of Ultrasonic Welding

  • Much faster than conventional adhesives or solvents.
  • Drying time is very quick.
  • The pieces do not need to remain in a fixture for long periods of time waiting for the joint to dry or cure.
  • The welding can easily be automated, making clean and precise joints.
  • The site of the weld is very clean and rarely requires any touch-up work.
  • The low thermal impact on the materials involved enables a greater number of materials to be welded together

 

Advantages:

  • Flexible and versatile with little tooling changeover or fixture modifications, consistent and repeatable, very rapid weld time confined to the bonding or joint area, can replace fasteners and adhesives.
  • It has 16 weld programs which include parameters like Trigger pressure, Weld pressure, Amplitude etc.

 

Part design –Ultrasonic Weld Joint

  1. Energy director: Define a place to start the weld
  2. Sonotrode contact: Allow the ultrasound to have a direct path to the joining area
  3. Support: Allow the bottom weld-part to resist deformation
  4. Melt encapsulation: Prevent the melt from leaving the joint
  5. Centering: Ensure a consistent alignment
  6. Volume and part travel: Allow the part to move freely and the melt to go somewhere
  7. Prevent hard stop
  8. Let the part sink into the melt during holding
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Joint Designs

The most commonly utilized joint designs that AMTEC recommends

  • Step Joint
  • Step Joint (chisel)
  • Tongue and Groove Joint
  • Mash Joint

These designs all utilize the most important design rules. The use of each design is subject to the specific application and requirements of the weld.

USW 13