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Basic principles for ultrasonics.
The basics and more.

Industrial ultrasonics is an acoustic principle. Vibrations are turned into heat and thus the plastic material melts. Let us explain the principles in detail and show you the large number of fascinating application options. Ultrasonic Welding Basics

Alle Thermoplaste lassen sich mit Ultraschall verschweißen, am besten sind harte, amorphe Kunststoffe wie PC, PS, SAN, ABS und PMMA. Sie haben sehr günstige Übertragungseigenschaften für die Ultraschallenergie; sind also auch bei größeren Dimensionen leicht und gut verschweißbar. Teilkristalline Kunststoffe wie PA, PP, PE und POM schmelzen generell schneller auf. Sie sind daher am besten im unmittelbaren Nahfeld der Sonotrode (Schweißwerkzeug) schweißbar.
Neben Kunsstoffen können auch Nichteisenmetalle wie Kupfer, Messing, Nickel und Aluminium verschweißt werden. Unterschiedliche Metalle sind mit Ultraschall sicher und fest miteinander fügbar.

Ultrasonic welding is a fast and economical, but also complex technology. To evaluate a welding task you need experts. In the lab, our engineers test the feasability of the application: Is the material weldable? Is the component design adequate? Is there a proper energy director, that will focus the ultrasonic waves to define the melt initiation?

Ultrasonic engineering includes all services to ensure that the weld process is working properly and can be implemented trouble-free in your production. This begins with the determination of the process parameters and goes beyond the construction of the weld tools and equipment to complete integration solutions into existing machines/production lines.

The ultrasonic generator converts the supply voltage (50 Hz and 230V) into a high frequency voltage of 20, 30, or 35 kHz which is converted into mechanical vibrations in the converter. The wave increases itself on its way from converter through the booster to the sonotrode. The sonotrode is the actual weld tool, transferring the vibrations into the component.

The amplitude is the movement of the weld tool, and more specifically, the deflection at which the stack expands and contracts – between 5 and 50 µm. As comparison: The diameter of a human hair is only 100 µm. The frequency is the number of oscillations per second. With ultrasonic welding, frequencies between 20 and 35 kHz are used. 35 kHz equal 35.000 movements per second.

Most sonotrodes are made of titanium because titanium is very hard and very durable against natural oscillation. Sometimes sonotrodes may be made from hardened steel or aluminum, depending on the application and the recommendation of the engineers in the laboratory.

No, ultrasonic frequencies between 20 and 35 kHz are not harmful to humans. Sometimes unpleasant whistling side noises will occur. Therefore machines in the lower frequency range often have sound insulation.

Ask for our service and maintenance agreements. We provide additional safety due to our 24-hour hotline, yearly machine checks, machine calibration, or software updates