Ultrasonic Welding Machine

Did you know? All the forms of plastic welding currently used in industry, ultrasonic welding is the most popular and versatile among them. There are good reasons for this. Ultrasonic welding can be used to weld a huge range of plastic components of all shapes and size which creates a strong and reliable bond. It is therefore extensively used across several industry sectors, for a variety of applications.

Ultrasonic welding uses locally applied, high frequency sound vibrations to displace plastic molecules along a join and create a stable, solid state bind between two components, held together in a pressurized environment. It requires no bolts, nails, solder or other joining material. Unlike some other forms of plastic welding, it produces very little in the way of fumes, dust or excess heat energy, making it a clean and energy efficient form of welding. It also has the significant advantage of being able to join certain dissimilar materials without having to resort to adhesives.

What Is Ultrasonic Welding Machine?

The development of commercial ultrasonic welding Machine in the 1960s completely transformed the potential of plastic manufacturing. Until this point, only hard plastic components could be joined together in a stable weld. This limited the potential of plastic for use in the manufacturing industry. In the early 1960s a form of ultrasonic welding was developed, using ultrasound-emitting probes to bond together plastic film into tubes and bags.

In 1965 the technique graduated from soft to rigid plastics and was put to use in the toy industry, making mass produced plastic toys cheap and accessible for the first time. From 1969 onwards, ultrasonic welding has been used to bond plastic components in the automotive industry, and then a growing list of other sectors in the ensuing decades.

Where To Use Ultrasonic Welding Machine?

Ultrasonic welding technology has progressed and diversified greatly since, and is now used in various specialist applications in different industries. These include:

• Medical Industry

Due to the fact that ultrasonic welding Machine does not involve adhesives or create dust (a potential contaminant), it can be used for a number of ‘clean’ medical products, including catheters, dialysis tubes, face masks, air filters and plastic textile garments.

• Packaging Industry

Ultrasonic welding machine is commonly used to seal containers, blister packs and cartons because of the strong bond it creates. Ultrasonic welding can form a hermetic seal around products containing hazardous materials, or high value products for additional retail security.

• Electronic & IT Industry

Thousands of different electronic components can be successfully joined through ultrasonic welding, for which other forms of ultrasonic welding machine are unsuitable.

Vibration welding, for instance, is unsuitable for welding microchips and electronic components because the vibrations can cause damage to tiny wires and circuits. Ultrasonic welding does not have this problem, so is frequently used for microchips, mini conductors, computer hard drives and other sensitive components.

• Aerospace and Car Industry:

Ultrasonic welding machine is as suitable for bonding medium sized components used in aerospace and automotive manufacturing, as it is for delicate parts. Specialist machines have been developed for these industries to serve specific purposes. It is a sign of the great flexibility of ultrasonic welding that machines can be built to produce components as distinct as car bumpers and headlight housing.

Buyers Guide to Buy Ultrasonic Welding Machine

When you keep in mind the things to consider, you can easily choose the best Ultrasonic Welding Machine .The key factor in selecting the one is what two metals you wish to fuse using that particular machine. Take a look at the below section:

• Amperage & Volt input

The input power fed to a Ultrasonic Welding Machine is important to know. Discussing the amperage first, a ultrasonic welding machine  amperage range is a key factor to consider. It exactly determines what you can and cannot weld. Most Ultrasonic Welding Machine can fuse different types of weldable metal. However, a welder with an appropriate amperage range is critical to weld various gauge sections.

The power supply transforms a low frequency, 50 to 60 kHz electric current to a high frequency, 20 to 40 kHz electric current. The application usually dictates which frequency is required. Most British manufactured ultrasonic welders fall into the 20 to 40 kHz range, but some can be as high as 15 kHz. Generally the higher the frequency, the smaller the tool, and the lower the wattage produced by the generator. For example, a 40 kHz is usually 800 watts, 20 kHz can be as high as 5,000 watts.

• Build quality

Your chosen Ultrasonic Welding Machine must last longer. It is not a good idea to frequently invest in a welder unit due to the hefty price. Make sure the materials used in the construction are of decent quality and they must assure durability. Some stick welders are made up of steel while some others are made from metals like carbon steel, medium carbon steel, and steel alloy.

• Duty Cycle

The duty cycle represents the amount of time you can constantly weld before you have to let the machine cool off. Generally, a full duty cycle is 10 minutes. The longer duty cycle, the more efficiently it can accomplish your job.  Also, it makes sure you need not face the overheating issue.

If you intend to use a Ultrasonic Welding Machine for home repair work or some other hobby welding tasks then a lower duty cycle is fine. However, for industrial applications, a higher duty cycle is required. The problem with a lower duty cycle is you need to stop every 2 minutes.

• Safety features

If your chosen Ultrasonic Welding Machine is not safe to use, it cannot provide you the maximum benefit. You may be prone to safety hassles. Hence, it is important to look for some important safety features. During the operation, the Ultrasonic Welding Machine usually get heated up. So, it is essential to prevent overheating.

Different safety features available in some Ultrasonic Welding Machine are over-load, over-voltage, under-voltage, over-current, overheat, anti-stick protection, and thermal overload protection. All thee safety features make sure it is safe to use a Ultrasonic Welding Machine unit.

With the help of thermal overload protection, the welder unit automatically shuts off before it gets extremely hot. Once it is shut off, it starts only when the unit is cooled down.

• Portability

The majority of Ultrasonic Welding Machine are portable. It is important to check portability because you occasionally need to accomplish the welding done out of your home. Due to portability, you can easily carry with you. The weight and build quality determine the portability. You can consider buying a lightweight welder for portability.

• Cost

The Ultrasonic Welding Machine cost differ with different brands. Choose according to your need.

Conclusion:

The Ultrasonic Welding Machine are famous for their superior speed and predictability. They are extensively used in home and industrial welding applications. All the Ultrasonic Welding Machine discussed above have several unique functions and operations fulfilling specific needs. Make sure you choose the ones that suit your requirements.