8 Advantages of Using Ultrasonic Welding | Read More - Dukane

Ultrasonic welding is a popular method of joining thermoplastic parts. It uses high-frequency mechanical vibrations to generate friction between two plastic components, resulting in sufficient heat to locally melt and bond the parts at their interface. There are many clear advantages to using ultrasonic welding over other assembly techniques, including:  

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Fast Cycle Times:

Ultrasonic welding delivers remarkably fast bonding. Most parts are bonded in less than three seconds, with the vast majority bonding in less than one second. With clever machine and part design, it is possible to process more than one part per second with a single welder.   

Cost Effective:

Ultrasonic welding is often one of the most cost-effective methods of plastic welding. The equipment is comparatively inexpensive and versatile and can often be used to weld multiple parts with a simple tooling change-over. Ultrasonic welding typically consumes less energy than other common plastic bonding techniques. By eliminating the need for adhesives or fasteners, this method not only reduces manufacturing time and complexity but also eliminates the ongoing cost associated with those extra materials.   

Versatile Application:

Ultrasonic welding is adaptable to a wide range of materials, including molded thermoplastic components, woven and nonwoven thermoplastic fabrics and films, and even some soft metals. It can also be used to cut or form other materials such as food products, packaging materials, thermoset resins like rubber or urethanes, and natural fibers like cloth. Additionally, ultrasonic welding can attach various thermoplastic materials to non-plastic parts through methods such as staking, swaging, and inserting.   

Precision:

Advanced ultrasonic welding equipment, such as the Dukane Infinity series of welders, can control an ultrasonic weld within a few microns of dimensional precision. Additional controls over energy and force provide multiple ways to achieve specific numerical targets in the bonding process.   

Highly Repeatable:

Ultrasonic welding machines offer extensive process controls, enabling precise management of the bonding process. They are ideally suited for modern manufacturing environments where repeatability and consistency across multiple machines and multiple facilities are crucial.   

Elimination of Consumables:

Ultrasonic welding is an excellent alternative to processes that rely on adhesives, mechanical design features, or fasteners to join parts. This method requires only the thermoplastic within one of the parts, eliminating the cost and complications associated with glues and fasteners.   

Versatile Equipment:

In ultrasonic welding, only the tooling is specific to a particular assembly. The horn (sonotrode) and holding fixture are designed for a specific task, but the rest of the equipment can be easily repurposed for different parts or processes. This flexibility allows you to weld multiple parts on a single system by simply changing the tooling. Additionally, you can often repurpose welding equipment when a project reaches the end of its life cycle.    

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Environmentally Friendly:

Ultrasonic welding requires only the welder, tooling, a small amount of electricity, and the parts themselves. This eliminates the need for harsh glues and chemical epoxies typically used for bonding. With proper machine design and safety measures, there are no harmful effects from being around ultrasonic welding equipment, making it a safe choice for any manufacturing environment. 

Welding is not new. It started in Egypt around 4,000 B.C. during the Bronze Age when soldiers fought with swords. The metals were heated and hammered into different tools.

This process remained unchanged until the early 19th century. By then, acetylene was discovered and used to heat the metal. In the middle of the 20th century, ultrasonic welding was discovered. It was introduced to bond metals quickly and at lower temperatures than conventional welding.

Arc welding joins metal to metal. It uses an electric arc that will generate enough heat to melt the material. When cooled, the molten metals solidify into a metallurgical bond. This method uses either direct or alternating current. It can either be manually guided or fully automated. Arc welding is popular in construction, welding pipelines, and repair of heavy equipment. It is also used in the fabrication of farm equipment, steel structures, ships, and vehicles.

What is Ultrasonic Welding

It is the type of welding that uses high-frequency ultrasonic vibrations. It can weld similar or dissimilar materials quickly and efficiently. There is no need for unsightly bolts, nails, solder, or adhesives. Ultrasonic welding is the top choice for clean, reliable, and precise joints.

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Advantages and Disadvantages

Both conventional and ultrasonic welding has their pros and cons. It all boils down to the manufacturer’s quality standards, preferences, and materials used. The number one consideration should be to manufacture consumer-friendly products at lower production costs. More importantly, welds should be tough enough to withstand pressures.

The following are the more common reasons for using these methods:

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