Everything You Should Know About Sonic Weld – Brief, Uses, & Work Mechanism
To get to the final product, plastic injection moldings are frequently machined or joined with additional components. There are a variety of methods for combining plastic parts, but sonic welding is a fast, clean, and effective way to join plastic pieces with a strong and lasting bond. Ultrasonic welding, vibration welding, and spin welding are all examples of friction welding processes. All of these ways work on the same basic premise: friction creates heat, which melts the plastic at the connection.
The most common approach, ultrasonic welding, uses ultrasonic energy to create surface and intermolecular friction, which generates heat and, in turn, forms a weld. Most thermoplastics are suitable for ultrasonic welding. Amorphous polymers are good for ultrasonically welding; semi-crystalline polymers, on the other hand, are more difficult to weld.
Brief About Sonic Weld
Sonic Weld also known as Ultrasonic Welding (USW) is a welding technology that uses high-frequency ultrasonic vibration to join two components together. Welding thermoplastic and dissimilar materials are the most prevalent use. USW can also be used to weld metal with a thin section.
Sonic Weld's main components include:
- Pneumatic press
- Booster
- Convertor
- Sonotrode
- Ultrasonic generator
- Fixture or Nest
The Work Mechanism of Sonic Weld
In the nest, the two plastic pieces that need to be linked are put together ( anvil or fixture)The horn is created to make touch with the piece's upper portion.
The two components are pressed together against the fastening. The pressure is applied with the help of a pneumatic or electric press.
The mechanical vibration is transmitted to the two plastic components by vibrating the horn vertically at a very high frequency (20 kHz to 40 kHz). This creates heat energy and melts the two surfaces at their contact tip.
The clamping force is eliminated after solidification, and the horn is withdrawn. The welded plastic item is removed in one piece from the fixture.
Applications Sonic Welding Is Widely Used
Ultrasonic welding is employed in applications involving similar and dissimilar junctions, as well as polymer welding. Metals, plastic sheets, and plastic films in various shapes such as wires (crossed or parallel), ribbons, and flat surfaces are all produced using this method. Set-ups are created for the material and part form necessary when combining different sorts of assemblies that can be supported on an anvil.
Hiring Sonic Weld Services
Choose a service provider that has years of experience, flexibility, and facilities to apply the finishing touches. One of the extra services we provide is sonic welding. In addition to our comprehensive range of plastic injection moulding services, we also offer machining, gluing, and multi-component assembly.
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