Principles of friction welding and ultrasonic welding

The working principle of ultrasonic plastic welding is: the machine converts electrical energy into ultrasonic energy through the ultrasonic transducer into ultrasonic energy (that is, high-frequency mechanical vibration energy with a frequency beyond the hearing threshold of the human ear), and the energy is conducted to the plastic workpiece through the sonotrod, and the joint surface of the plastic workpiece is melted after severe friction with an ultrasonic frequency of tens of thousands of times per second and a certain amplitude. The brief pressure maintained on the workpiece after the vibration stops causes the two weldments to solidify as one in a molecularly linked manner.

Generally, the welding time is less than 1 second, and the welding strength obtained is comparable to that of the body. NC series ultrasonic plastic welding machine can be used for butt welding of thermoplastics, and the welding head can also be replaced according to customer needs, which is used for riveting, spot welding, embedding, removal and other processing processes.

Vibration welding is a friction welding process in which the welded parts are rubbed together under pressure until the friction and shear heat generated causes the scalcous surface to reach a fully molten state. Once the molten film has formed and penetrated deep enough into the joint area, the relative movement stops, and the weld cools and solidifies under pressure. Vibration welding is suitable for almost all thermoplastics, medium or large parts with a permissible unconstrained movement weld in the direction of reciprocating motion.

Vibration welding is particularly suitable for thermoplastic materials, including amorphous resins such as ABS PC, PVC, PMMA and PES; Semi-crystalline resins such as HDPE, PA, PP, TPO.

The principle of ultrasonic welding is to use high-frequency vibration waves to transmit to the surfaces of two objects to be welded, and under pressure, the surfaces of the two objects rub against each other to form a fusion between molecular layers.

Ultrasonic welding is the conversion of 50 to 60 Hz current into or 40kHz of electrical energy through an ultrasonic generator. The converted high-frequency electrical energy is again converted into mechanical motion of the same frequency by means of a transducer, which is then transmitted to the sonotrode via a set of amplitude-changing rod devices that can change the amplitude. The sonotrode transfers the received vibration energy to the joint of the workpiece to be welded, where the vibration energy is converted into heat by friction to melt the plastic.

Ultrasound can be used not only to weld hard thermoplastics, but also to process fabrics and films.

The main components of an ultrasonic welding system include ultrasonic generator, transducer, luffing rod, sonotroduct, tool, tool, and frame.

Ultrasonic metal welding is a technology that uses high-frequency ultrasonic waves generated by mechanical vibrations to weld metal materials. It is widely used in automotive, electronics, medical equipment and other industries, especially for the welding of thin-walled and fine-density metal components.

Ultrasonic metal welding works by placing two metal parts to be welded between the welding heads and applying a certain amount of pressure. The electrical energy is then converted into mechanical vibrations by means of an ultrasonic generator, usually at a frequency between 20 kHz and 70 kHz, while the vibrations are transmitted to the welding head.

The vibration in the welding head repeatedly compresses the two welded parts downwards and quickly returns to their original positions. Such movements create microscopic friction and shear forces on the metal surface, resulting in high-temperature, high-pressure weld zones between the contact surfaces. This effect also satisfies conditions similar to those of thermoplastic welding, so metal parts can be welded together.

Compared with traditional metal welding methods, ultrasonic metal welding has the following advantages:

Welding is fast and late, usually taking only a few seconds to complete.

There is no need to use soldering materials, reducing costs and process requirements.

A wide range of metal materials can be welded, including different kinds and different thicknesses.

Compared to other metal welding methods, ultrasonic metal welding has a very small impact on the welding area, produces low distortion, and requires very little heating.

Therefore, ultrasonic metal welding has been widely used in automobiles, electronics, medical devices, and other fields, and has advantages in terms of efficiency, environmental protection, and sustainability.

Super Pai Qingshu sonic metal welding uses the high-frequency vibration wave of Chashan to transmit to the metal surface to be welded, and under the condition of pressure, the two metal surfaces rub against each other to form a molten dust macrosynthesis between the molecular layers.

The common ultrasonic welding methods can be divided into four types: ultrasonic welding, ultrasonic riveting, ultrasonic spot welding and ultrasonic implantation according to the connection method.

On the welding equipment, by adjusting the pressure, amplitude and other parameters, to ensure that the sonotrode contacts the welding surface and applies pressure, the sonotrode produces ultrasonic high-frequency, the upper workpiece vibrates to generate heat, and the lower workpiece is the part that accepts the pressure, which is placed in the bottom die and does not move, and the three are combined to complete the fusion of the workpiece, and then the sonotrode stops vibrating, maintains the pressure, and cools the melting position to achieve the purpose of perfect welding.

The working principle is similar to welding, the method is to penetrate a plastic rivet into another material, the welding surface of the welding head is designed to be rivet-coated, and the plastic rivet is welded and coated on another material by high-frequency vibration heat generation.

The working principle is similar to welding, in which the sonotrode is designed in the shape of a pistol, with one end of one plastic workpiece penetrated and fused to the plane of another plastic workpiece. The advantage is that the welded surface does not require any special design, tongue tenon and rivet, and is often used for large flat workpieces.

The working principle is similar to welding, the method is to place the embedded metal nail in the plastic workpiece, and then the welding head touches the metal nail and vibrates to generate heat, so that the nail is embedded and fixed in the plastic workpiece.

The principle of ultrasonic plastic welding.

When ultrasonic waves act on the contact surface of thermoplastic plastics, tens of thousands of high-frequency vibrations per second will be generated, and the high-frequency vibrations that reach a certain amplitude will transmit ultrasonic energy to the welding area through the upper weldment, and the welding area will produce local high temperature because the sound resistance at the interface between the two welds is large. Due to the poor thermal conductivity of plastics, they can not be dissipated in time for a while, and they gather in the welding area, causing the contact surface of the two plastics to melt rapidly, and after adding a certain pressure, they are fused into one. When the ultrasonic wave stops working, let the pressure continue for a few seconds to solidify and form, so that a strong molecular chain is formed, and the welding strength can be close to the strength of the raw material.

The quality of ultrasonic plastic welding depends on the amplitude of the transducer welding head, the pressure applied and the welding time, the welding time and the pressure of the sonotrode can be adjusted, and the amplitude is determined by the transducer and the amplitude rod. There is a suitable value for the interaction of these three quantities, and when the energy exceeds the appropriate value, the melting amount of the plastic is large, and the weld is easy to deform; If the energy is small, it is not easy to weld, and the pressure applied should not be too large. This optimal pressure is the product of the side length of the welded part and the optimal pressure per 1mm of the edge.

Principle of ultrasonic metal welding.

The principle of ultrasonic metal welding is a special method of connecting the same metal or dissimilar metal by using the mechanical vibration energy of ultrasonic frequency (more than 16kHz) When the metal is ultrasonic welding, it neither transmits current to the workpiece, nor applies a high-temperature heat source to the workpiece, but under static pressure, the vibration energy of the wire frame is converted into friction work, deformation energy and limited temperature rise between the workpieces The metallurgical bond between the joints is a kind of solid-state welding realized without melting the base metal Therefore, it effectively overcomes the phenomena of spatter and oxidation generated during resistance welding Ultrasonic metal welding machine can carry out single-point welding, multi-point welding and short strip welding of non-ferrous metal filaments or sheet materials such as copper, silver, aluminum, nickel and other non-ferrous metals It can be widely used in the welding of thyristor leads, fuse pieces, electrical leads, lithium battery pole pieces and tabs.

Working in a company that produces ultrasonic welding machines, the principle of ultrasonic welding can be memorized, so let's share it.

Ultrasonic welding is a high-tech technology that can be used in all hot melt plastic products without the need for solvents, adhesives or other auxiliaries. It can improve productivity, improve product quality, low cost and improve production safety.

Ultrasonic welding is to convert the mains AC (220-240V, 50 60Hz) into a high-frequency and high-voltage signal through the power supply box, and then convert the signal into high-frequency mechanical vibration through the transducer system, which is added to the plastic products, so that the friction between the two parts of the plastic products is generated, and the temperature rises, and when the temperature reaches the melting point of the product itself, the product interface is rapidly melted, and the product is cooled and shaped under a certain pressure, so as to achieve the welding effect.

The principle of ultrasonic metal welding is a special method that uses the mechanical vibration energy of ultrasonic frequency (more than 16kHz) to connect the same metal or dissimilar metal When the metal is carried out ultrasonic welding, it neither transmits current to the workpiece, nor applies a high-temperature heat source to the workpiece, but only converts the vibration energy of the frame into friction work, deformation energy and limited temperature rise between the workpieces under static pressure. The metallurgical bonding between joints is a kind of solid-state welding achieved without melting the base metal, so it effectively overcomes the spatter and oxidation phenomena generated by resistance welding. Ultrasonic metal welding machine can perform single-point welding, multi-point welding and short strip welding of non-ferrous metal filaments or sheet materials such as copper, silver, aluminum, nickel, etc.

It can be widely used in the welding of thyristor leads, fuse pieces, electrical leads, lithium battery pole pieces and tabs.

20,000 vibrations per second are applied to the workpiece.