Ultrasonic welding is used widely in many industries -- including shoe manufacturing and auto making. How well do you know how this method uses sound to do what high temperatures normally do. Test your knowledge now.
Ultrasonic welding was first introduced in the 1940s.
Plastic materials are most commonly and easily bonded together by ultrasonic welding techniques.
The sound waves vibrate the materials. The rubbing makes friction that creates the heat.
The horn focuses the ultrasound vibrations and delivers them to the materials to be welded.
The heat made by friction melts the plastics together.
New Balance uses ultrasonic welding to bond materials with a hot melt film and to emboss materials.
Ultrasonic welding is a low temperature process.
Ultrasonic welding is fast, cheap and safe.
The booster amplifies the sound waves coming from the transducer.
Another name for the horn is the sonotrode. It focuses and delivers the sound waves to the materials to be welded.
Most ultrasonic welding machines use frequencies in the range of 20 - 40 kHz.
The heat made by friction burns away oxides and contaminants from the two metal surfaces. The metals can then bond together.
Ford Motor Company has explored using ultrasonic welding to make aluminum chassis in cars.
Ultrasonic welding is faster than soldering or conventional welding.
Ultrasonic welding can only produce welds of about a millimeter or so. So, it would not be appropriate for steel girders. Conventional welding would be used.
Ultrasonic welding can potentially damage your hearing. So, ear protection is commonly used.
The transducer or converter changes the high frequency electricity into high frequency sound (ultrasound).
Ultrasonic welding is influenced by the frequency of the sound waves, the pressure used to hold the materials together, and the time of the weld.
Copper and aluminum are the most common metals welded utrasonicaly. Copper wiring and aluminum sheets have been used.
Ultrasonic welding is used to make medical devices and product packaging.