How much is an ultrasonic welding machine?
Ultrasonic welders cost anywhere from $18,000 to $45,000, depending on power capacity and bells and whistles, such as statistical process control packages. A basic 20-kilohertz, 2.5- to 3.5-kilowatt ultrasonic metal welding system can be acquired for around $30,000.
What is an ultrasonic welder used for?
Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. It is commonly used for plastics and metals, and especially for joining dissimilar materials.
What are the advantages of ultrasonic welding?
Ultrasonic welding offers some key advantages over other forms of welding:
- It saves time. It is much faster than traditional welding methods, as virtually no time is needed for drying or curing.
- It saves production costs.
- It produces a high-quality bond and a clean, tight seal.
What is an ultrasonic seal?
Ultrasonic sealing technology uses acoustic vibrations to generate heat at a molecular level inside of the film itself. This molecular friction allows the material to seal without the need for direct heat on the material from the VFFS seal jaws. Also, it is capable of sealing through product caught in the seals.
What is ultrasonic metal welding?
Ultrasonic metal welding is a solid-state bonding process in which ultrasonic vibrations create friction-like motion between two surfaces, causing deformation and shearing of asperities to bring metal-to-metal contact and bonding.
What are the disadvantages of ultrasonic welding?
A limitation of ultrasonic welding is that with current technology, large joints cannot be welded in a single operation. In addition, specifically designed joint details are required. Ultrasonic vibrations can also damage electrical components, although the use of higher frequency equipment can reduce this damage.
What is the basic principle of ultrasonic welding?
The process relies on high-frequency (ultrasonic) vibrations being generated and applied to the parts via a horn. Welding occurs as the vibrations are absorbed in the interface between the two parts, generating friction and causing the plastic to melt.
What is the disadvantage of ultrasonic welding?
What materials can be ultrasonic welded?
For example, ABS, acrylic, polycarbonate and PVC are amorphous polymers with little or no crystalline structure. These plastics are well suited to ultrasonic welding. Ultrasonic welding of two parts made from the same plastic material will usually obtain the best result.
Is ultrasonic welding safe?
Safety: Using ultrasonic welding equipment is extremely safe compared to other welding techniques. The ultrasonic energy is highly targeted, reducing the risk of dangers due to excess electrical energy.
Is ultrasonic welding waterproof?
Sonikel Ultrasonics, designs and manufactures Ultrasonic Welding Machine for waterproof welding of ABS and Polycarbonate. Supporting by Industry 4.0 theory, ultrasonic welder designed by Sonikel, lets mass production and automation. There will be no need to use any chemicals for sealing plastic parts to each other.
What you should know about ultrasonic welding?
All ultrasonic welding systems are composed of the same basic elements: A press, usually with a pneumatic or electric drive, to assemble two parts under pressure A nest or anvil or fixture where the parts are placed and allowing the high frequency vibration to be directed to the interfaces An ultrasonic stack composed of a converter or piezoelectric transducer, an optional booster and a sonotrode (US: Horn).
Why to use ultrasonic welding methods?
or mechanical fasteners.
Some of these advantages of ultrasonic welding are explained in more detail below: Speed: One of the most significant advantages of ultrasonic welding is the fact that it is an exceptionally fast process. Safety: Using ultrasonic welding equipment is extremely safe compared to other welding techniques. Reliability: Once assembled and tested, ultrasonic welding equipment will function with a high level of reliability.
How does ultrasonic welding work?
Ultrasonic welding works by high-frequency ultrasonic acoustic vibrations. The piezoelectric effect allows the conversion of high-frequency electrical energy to high-frequency mechanical energy. The vibrations are applied to the materials being welded by a vibrating tool.