Understanding ultrasonic welding

Understanding ultrasonic welding

Ultrasonic welding is a process that uses the ultrasonic vibration of high frequency to weld two thermoplastics together. It is a common industrial technique to bind without the need for soldering materials or adhesives.

It is used to create plastic-to-plastic joints, install windows in housing, and insert mechanical fasteners into plastic injection moulded parts.

What sets ultrasonic welding apart from standard welding?

There’s no waiting time with ultrasonic welding for machines to warm up or the materials to be heated. In addition, ultrasonic welding creates air and watertight seals, consumes less energy, and leave no solvent or filler waste.

Furthermore, the ultrasonic welding process happens in seconds, saving time and, subsequently, production costs. Ultrasonic welding is a safer process compared to other welding methods since there are no fumes from soldering. Ultrasonic welds are as strong and durable as standard welds. They can be used to bond the metal in less time and at lower temperatures, making it ideal for the automotive industry, where there’s a high demand for cost and weight limitations.

Material consideration

When bonding two thermoplastic parts through ultrasonic welding, the materials must be chemically compatible to ensure a molecular bond. Thermoplastics with the same chemical properties will weld to themselves, while different thermoplastics are only compatible if their melt temperatures are within 6°C and have a similar molecular structure.

Joint design considerations

For the best assembly results, the joint design of the mating pieces is critical. Each part’s joint design relies on several factors, including the type of plastic and shape of the part. The basic requirements in joint design calls for a small initial and uniform contact area and means of alignment.

Advantages of ultrasonic welding

Ultrasonic welding is an assembly process that is fast, clean, efficient, and repeatable. In addition, it produces strong, integral bonds and consumes very little energy. It is more environmentally friendly since it uses no solvents, adhesives, mechanical fasteners, or external heat to create a solid and clean finish.

Contact M.E.E for details

If you have any questions about ultrasonic welding, you can get in touch with us today for more information on our products, services, and spares.

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