Ultrasonic welding near me is a plastic fabrication process that produces strong, reliable bonds. It’s a clean, automated alternative to adhesive and mechanical joining methods, which require curing times and messy cleanups. It works with a variety of materials, including acrylic, acrylonitrile butadiene styrene (ABS), high impact polystyrene (HIPS), nylon, polycarbonate and polypropylene. It also has the ability to assemble and weld thermoplastic to thermoset prepreg composites and metals.

A typical ultrasonic welder consists of three core components: the converter, booster and horn. The converter takes standard electrical power at 60 Hz and converts it to an operating frequency of up to 20 kHz, which is then fed through the booster to the horn. The horn then transmits the mechanical vibration to the parts that are to be welded. The vibration and mechanical pressure cause the matrix system of the part to melt and flow together, forming a molecular bond.

There are a number of common troubleshooting issues that can arise during an ultrasonic welding project. Some may be solved by adjusting the settings, while others will require the services of an experienced repair technician.

Marking

Marking is a common problem that occurs when the horn of an ultrasonic welder heats up too much, dispersing energy beyond the area being welded. It can be resolved by reducing the weld time, trigger force and down speed to reduce the amount of energy being applied. In some cases, a redesign of the part to reduce localized high spots may be needed as well.