The Pennsylvania State University at Erie

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Ultrasonic/Vibration/Hot Gas Welding

• Presented by
• Kevin Himes
• Marty Timm
• James Scott

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Ultrasonic Welding

• Basic Purpose Process
• Produce hermetic bonded joints
• Mechanical movement
• High frequency sound energy
• Oscillating horn
• 20 to 40 KHz
• Very quick cycles

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Ultrasonic Welding

• Equipment

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Ultrasonic Welding

• Types of Joining
• Welding
• Staking
• Inserting
• Swaging
• Spot Welding
• Slitting
• Textile/Film Sealing

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Ultrasonic Welding

• Welding Parameters
• Weld by Time
• Weld by Energy
• Weld by Collapse Distance

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Ultrasonic Welding
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Ultrasonic Welding
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Ultrasonic Welding

• Appliances
• Automotive
• Electrical
• Medical
• Packaging
• Toys

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Ultrasonic Welding

• Materials
• Most Thermoplastics
• Stiffer easier to weld
• Higher melt temperatures require more energy
• Similar molecular structures
• Crystalline only weldable to themselves

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Ultrasonic Welding

• Advantages
• Energy efficiency
• High productivity with low costs
• Ease of automated assembly lines
• Fast joining times

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Ultrasonic Welding

• Disadvantages
• Limited component length of 250mm
• Bondable materials

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Vibration Welding

• Basic Purpose and Process
• Produce strong, pressure-tight welds
• Rubbed together under pressure
• Suitable frequency and amplitude
• 100-500 Hz
• 1-4 MPa pressure
• 1-5 mm amplitude
• Rapid cycles

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Vibration Welding
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Vibration Welding

• Materials
• Both amorphous and semicrystalline
• Injection molded, extruded, blow molded,
  thermoformed, or stamped
• Crystalline thermoplastics
• Acetal, polyethylene, nylons and polypropylene

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Vibration Welding

• Typical Applications
• Automotive
• Aerospace
• Appliance
• Medical
• Electrical / Electronic
• Recreational

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Vibration Welding

• Advantages
• Large complex linear joints
• Applicable to most polymers
• High production rates
• Number of components simultaneously
• Simplicity of tooling

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Vibration Welding

• Disadvantages
• Materials with similar melt temps
• Limited part geometry

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Vibration Welding

• New advancements
• Ability to vary pressure during cycle
• Development of equipment or orbital welding

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Hot Gas Welding

• Process
• Hot gas
• Two thermoplastic materials
• Filter rod

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Hot Gas Welding

• Equipment
• Heater unit
• Nozzle
• Remote air compressor or integral blower

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Hot Gas Welding

• Two main types
• Speed Welding
• Round Nozzle Welding

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Hot Gas Welding
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Hot Gas Welding

• Advantages
• Cheap
• Simple equipment
• Simple Operation

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Hot Gas Welding

• Disadvantages
• Limited Materials
• Lower Strength