What Happened to Your Ultrasonic Weld Quality?

The most important factor in troubleshooting problems in ultrasonic welding is

understanding the fundamentals of the process. With this basic knowledge, most
problems can be easily diagnosed and resolved. Even so, sometimes your time-tested
weld recipe may suddenly fail for no discernible reason.

Perhaps your ultrasonic welder has been running the same application for months,
maybe years, with no problems. Abruptly, this cheery continuity is disrupted. Has
your weld strength decreased? Are you seeing excessive flash? Does your welder
overload as soon as the cycle starts? Here, we will discuss a few unseen factors that
can cause sudden changes in your ultrasonic weld quality and how to prevent and
correct them.

KNOW THE BASICS
Ultrasonic welding works by applying a vibration at a frequency of 15 to 70 kHz to a
plastic part. This vibration is generated through the use of piezoelectric ceramics in
the transducer, that convert an electrical signal into mechanical motion. The
transducer creates a vertical vibration that is then translated through the booster,
and subsequently, the ultrasonic horn. The ultrasonic horn is typically designed to
contact the part directly above the weld area so that the vibrations can travel though
the upper part to the weld area.


The ultrasonic vibrations create cyclical strain at the weld area, which generates heat
that melts the plastic in a restricted area and welds the two parts. Because the
ultrasonic vibration acts on the entire weld surface, an energy director is often added
to control the melting and reduce the amplitude necessary to achieve a weld.

It is important to prevent metal-to-metal contact on your ultrasonic horn to increase
its longevity. Because the horn is a tool with acoustical properties, users should be
careful to preserve its structural integrity. Any nicks or gouges in the surface of the
horn act as stress concentrators that can rapidly lead to cracks when the horn is in
use.

WARNING SIGNS
Many signs can indicate a change in your ultrasonic welding process. Some indications
of a problem with your part include decreased weld strength, increased flash, and the
appearance of cosmetic damage. Some things that signify a problem with the welder
or ultrasonic horn are an increased wattage draw, a change in the sound of your weld
(typically apparent on lower-frequency welders), and overloading.

The first step in eliminating unseen problems is to record your welding setup. Make a
Weld Process sheet that includes information such as your weld parameters (weld
time, hold time, trigger mode, amplitude); manual settings (thruster height,
pressure); and the critical dimensions of your part (diameter and energy-
director/shear-joint size). Also include photos of the welder, showing the alignment
and design of the horn and fixture. Refer to this document when problems ariseit
may save you a lot of time and trouble.

There are many not-so obvious factors that can negatively impact your ultrasonic
weld quality. One of the most frequent causes of problems in a long-running process is
wear on the mold that produces the parts to be joined. This is a slow, but sure, event
in any molding process. Because most joint designs are relatively small compared with
the size of the overall part, changes in their size or shape may go largely unnoticed.
For many applications, a change in shear width from 0.016 in. to 0.020 in. can make a
huge difference in weld quality. Such changes can be caused by just 0.002 in. of mold
wear on each part.

Another important factor is environmental changes such as ambient heat, cold, or
humidity. Humidity is a particular concern if you are using a hydrophilic material such
as nylon, polycarbonate, or polysulfone. Very cold temperatures can cause polymers
to become brittle, which may cause them to crack rather than weld at a normal
welding pressure. High heat can lead to longer solidification times, causing problems
if you are working with short hold times.
Some materials are less sensitive to process changes. Try switching to an easily
welded material, like ABS, to achieve greater consistency in your process.

Probably one of the most overlooked factors contributing to ultrasonic welding
problems is changes in the time from molding the part to welding the part. Proper
ultrasonic welding setup can be drastically different when welding cold parts as
opposed to welding hot parts. It is generally not a good idea to weld cold parts to
hot parts.

If at all possible, leave plenty of time for the part to cool after molding before
welding. Hot parts are more difficult to control and can cause inconsistency in your
weld process. Also, try to perform the welding operation in a climate-controlled
environment to eliminate seasonal effects on your process. This is especially
important in humid regions.

MORE FACTORS TO CHECK
Sometimes poor ultrasonic welds can be traced back to the injection molding process.
Injection mold wear can lead to a rounded energy director in the part (upper right),
which produces a weak weld (lower right). A well-maintained mold produces a sharply
pointed energy director (upper left), which produces a stronger weld (lower left) with
lower welding amplitude and less flash.

If you know it is not your parts causing the problems, it could be your ultrasonic
tooling. Occasionally a horn will develop a crack. While most horns will not run at all
after forming a crack, some do. Those will often emit a high-pitched ringing sound or
run at a higher wattage than normal. It is very important to discontinue use of a
cracked horn because it tends to put excess stress on the transducer and can lead to
broken piezoelectric ceramics.

Probably the easiest diagnostic test is to mix-and-match your ultrasonic stack if you
have multiple welders of the same frequency. Try the horn with a transducer and
booster that have been working well. If all is good after this switch, then you know
the horn is not the problem. Likewise, you can put a working stack in a questionable
welding machine. This is a quick and easy way to locate the trouble spot in your
machine without any special equipment.

If you find that the problem is your horn, check it for cracks. To locate cracks in a
horn, spray it with a foaming cleaner. Then use the test feature on your welder to
introduce short bursts of ultrasonic energy into the horn. The cleaner will collect in
the crack and turn a blackish color. WD-40 oil can be used if a foaming cleaner is not
available.

Finally, the welding fixture has a significant effect on the accuracy and precision of
your welds. Make sure the fixture is providing support to the entire joint area, and
that there is no room for misalignment of parts during loading. When welding softer
materials such as polyethylene and polypropylene, be sure that there is support
around the joint area in both lateral and vertical directions. Soft materials tend to
deform outwards, which will hinder or prevent proper welding.



How does your Ultrasonic Probe/Stack work?
Ultrasonic Probe
Plastic welding is the most common application of ultrasonic assembly. To perform ultrasonic
plastic welding, a vibrating tip is brought into contact with one of the work pieces as shown in
Figure 11. Pressure is applied and ultrasonic energy travels through the material, increasing
the kinetic energy (or heat) at the contact point of the two parts. The heat melts a molded
ridge
of plastic on one of the pieces and the molten material flows between the two surfaces.
When the vibration stops, the material solidifies forming a permanent bond.



Ultrasonic Probe Configuration
A basic ultrasonic probe consists of:
1. A housing which contains the transducer which converts electrical energy into
mechanical vibrations.
2. A horn to transfer the mechanical vibrations from the transducer to the parts to be
welded. A basic ultrasonic probe is shown in Figure 12. As indicated, the horn is
secured to the transducer with a threaded stud. The transducer housing also has a
connector for attaching the high voltage coaxial cable which delivers the high
frequency electrical signal for exciting the transducer. This signal is supplied by a
separate ultrasonic generator.


Transducer
The transducer supplies the ultrasonic vibrations by means of piezoelectric converters which
transform electrical energy into mechanical movement. Power applied to the transducer at
20kHz can range from less than 50 Watts up to 3000 Watts.



The transducer is made from a number of polycrystalline ceramic elements separated by thin
metal plates, clamped together under high pressure. When an alternating voltage (dV/dt) is
applied to the converters (or ceramics), a corresponding electric field (dE/dt) is produced
which results in a variation in thickness (dL/dt) of the ceramic elements. This variation in
thickness induces a pressure wave (dP/dt). Because the molecules or atoms of a solid are
elastically bound to one another, the pressure wave results in a wave propagating through the
material which is reflected by the ends the metal mass of the converter.

See Figure 18 for a graphical representation of this. When the length of the assembly is
tuned to its frequency of excitation, it resonates and becomes a source of standing waves. A
typical transducer without its housing is shown in Figure 13. The output amplitude from a
20kHz transducer is only about 20 microns (0.0008 inches), so this amplitude needs to be
amplified by the horn (and possibly a booster) to do useful work.

Ultrasonic Horn
The horn acts as an acoustic waveguide or transformer to amplify and focus the ultrasonic
vibrations to the work piece. The ultrasonic horn has three primary functions:
1. It transfers the ultrasonic mechanical vibrational energy (originating at the transducer)
to the plastic parts through direct physical contact, and localizes the energy in the
area where the melt is to occur.
2. It amplifies the vibrational amplitude to provide the desired tip amplitude for the
thermoplastic and weld process requirements.
3. It applies the pressure necessary to form the weld once the joint surfaces are melted.



The ultrasonic horn is precision machined and designed to vibrate at either 15kHz, 20kHz,
30kHz, 40kHz, 50kHz or 70kHz. Figure 14 shows five aluminum alloy horns ranging from
15kHz to 50kHz. The higher the frequency, the shorter the acoustic wavelength, and
consequently the smaller the horn. Notice that the 30Khz horn is only half the length of the
15kHz horn. The tuning of an ultrasonic horn is accomplished using electronic frequency
measurement. Inherent variations in material composition prevent tuning by dimensional
machining alone. Horns are usually manufactured from highstrength aluminum alloys or
titanium. Both metals have excellent acoustical properties to transmit the ultrasonic energy
with very little attenuation.

There are many different ultrasonic horn shapes and styles depending upon the process
requirements. Factors which influence the horn design are the materials to be welded and the
method of assembly. The gain of the ultrasonic horn is determined by its profile. Figure 15
shows four different gain profiles. The input vibration amplitude to a horn from a 20kHz
transducer is only about 20 microns. This is not enough to generate enough friction achieve a
melt temperature for most thermoplastics. Therefore the horn must amplify the mechanical
vibration so that the amplitude is sufficient to melt the thermoplastic. The amplitude at the
tip of the horn typically ranges from 30 to 125 microns (1.2 to 5.0 thousandths of an inch) at
20kHz.




An optional threaded tip can also be used when the application calls for staking, a swagging
profile or a pointed spot weld. In Figure 11, one of the plastic parts had a small ridge used to
initiate the melt process. Here in Figure 16, the tip provides the energy director since there
is only one piece to be melted in a staking operation. Replaceable tips are not commonly used
in highvolume production environments. For longterm or highwear production, a horn with
a custom machined tip coated with chrome, carbide or titanium nitride will provide excellent
wear resistance.



As the frequency increases, vibration amplitude typically decreases. Higher frequencies are
used for seaming of thin materials and delicate parts that do not require a lot of amplitude.
Since the horns become smaller at higher frequencies, closer spacing can also be achieved.
Some factors to consider for highfrequency (e.g. 40kHz) ultrasonic welding versus lower
frequency (e.g. 20kHz) ultrasonic welding are listed here.
1. For a given amplitude, stress in the horn increases at higher
frequencies.
2. Wear on the horn is greater at high frequencies.
3. Clean and flat mating surfaces between the horn, booster and transducer are more
critical as the frequency increases. At 40kHz, surface flatness specifications are
between 0.0005" and 0.001" (13 to 25 microns).
Booster
The primary function of a booster is to alter the gain (i.e. output amplitude) of the probe. A
booster is amplifying if its gain is greater than one and reducing if its gain is less than one.
Gains at 20kHz typically range from less than onehalf to about three. A booster designed to
be mounted in a fixture between the transducer and horn is shown in Figure 17. This is
commonly referred to as a probe stack. Since the horn cannot be clamped, only the
transducer and booster can be secured. Therefore a secondary function (and sometimes sole
purpose) of a booster is to provide an additional mounting location without altering the gain
when the probe stack is secured in a press. The neutral (1:1) or coupling booster is added
between the transducer and horn and mounted in the press by its mounting ring which is
placed at the nodal point (where the standing wave has minimal amplitude). See Figure 18
for a graphical representation. Note that the maximum stress occurs at the nodal points.






The 6 quick steps to a successful ultrasonic assembly
Do you have an application that you think could be ultrasonically assembled? Wondering how
to get from a couple of pieces of plastic to an assembled part?

This is how our sales engineers tackle an application. While we dont expect our customers to
perform each of these steps, its important they be involved in this process. That way theyll
have a better understanding of their systems and know how to maximize the ultrasonic
equipments potential.

Step 1 - Determine the feasibility of ultrasonics

First examine the components to be ultrasonically assembled. They must be thermoplastics,
and if dissimilar plastics are to be welded, they must be compatible (refer to Thermoplastic
Compatibility Guide. The parts must also be designed so ultrasonic energy can be efficiently
transmitted to the joint.

Using the Amplitude Reference Chart, determine the amplitude requirements of the
thermoplastic youre using. If possible, process a few parts to verify you have sufficient
amplitude. Consider using special ultrasonic horn coatings or horn materials if fillers or
additives are used in the plastic components.

The last step is to consider your ultrasonic tooling options. Is it even possible to build an
ultrasonic horn that will provide the necessary amplitude to the part? Will you need multiple
horns or a composite horn? Can the parts be properly supported in a fixture?

Step 2 Choose the right ultrasonic welding equipment

Once you determine ultrasonics is a viable assembly method for your application, its time to
choose your welding equipment. Your application and future project needs will dictate
whether you need 15, 20, 30 or 40 kHz equipment. The 20 kHz ultrasonic welding system is
more versatile, as it can process a variety of part sizes. Its also ideal when higher amplitudes
are needed to melt the plastic. A 40 kHz ultrasonic welding system is usually used for smaller,
more delicate applications. Your application will also determine the wattage of your
generator (200 to 5,000 watts). Traditionally, the bigger your part and horn, the more
wattage youll need to run the horn at full amplitude.

How youll apply the ultrasonic energy to your parts is another consideration. Hand-held
probes are ideal for applications where its more convenient to bring the ultrasonics to the
part. When control and repeatability are critical, a press system would be recommended. If
production rates require speeds that exceed what could be achieved by a standard press, a
rotary index parts handling system should be used. Custom mounting and automation of
ultrasonic thrusters are other possibilities.

Your ultrasonic sales engineer can help you design your system to meet other specific
application needs such as process control and SPC, cooling requirements, and sound
enclosures.

Step 3 Assemble and Install the ultrasonic tooling

Because transducers alone cannot generate enough amplitude to melt the plastic material,
your ultrasonic tooling and applications engineer will determine the gain factor thats needed
from the horn to match the amplitude requirement of the thermoplastic. Based on that gain
factor, he or she will select the appropriate booster and horn combination.

Youll need to assemble the transducer, booster, and horn but first examine all mating
surfaces for flatness and cleanliness. Remove any foreign matter from the threaded studs and
mating holes. Coat one contact surface of each stack component with a thin layer of high
pressure grease but do not grease the studs. Thread the components together and tighten by
applying a torque of no less than 13 foot-lbs (17.63 Newton-meters), but no more than 18
foot-lbs. (24.40 Newton-meters).

Once youve assembled the stack, install it into your system by following the easy directions
in the operations manual. Make sure it aligns with the fixture; use feeler gauges or carbon
paper if this becomes difficult.

Step 4 Set up the welding equipment

After following the simple setup procedures in the operations manual, you should be ready to
set the initial press force, trigger force, weld time, and velocity. If your application requires
precise melt velocity during the weld cycle, use hydraulic speed control, like the Kinechek
option, which is available on Dukane ultrasonic welding systems. Set the mechanical stop (so
the horn and fixture dont accidentally contact), then determine whether the ultrasonics
need to be activated before contacting the parts. If so, use the pre-trigger feature.

If youre using a process controller, determine and set the most effective primary process
control. Welding by distance, peak power, and absolute distance are the most common
controls, although welding can also be controlled by time and energy.

Step 5 Adjust the setup

After youve set up your ultrasonic tooling and welding equipment, dont go into full
production run a batch or two of sample parts. Examine and test (as needed) the assembled
parts. If process adjustment is needed, refer to the application troubleshooting section in the
Guide to Ultrasonic Plastics Assembly to help diagnose probable causes and solutions.

Step 6 Maintain proper operating conditions

Ultrasonics is a low maintenance process, and Dukanes ultrasonic welding equipment comes
with a 3-year warranty. However, to maximize your welding equipments life and
performance, its important to do some minor cleaning and inspecting after every 500 hours
of operation. This includes: removing dust/dirt from the guide rods; applying light oil to the
exterior of the air cylinder rod; inspecting wiring to the thruster head; inspecting the air
filter; tightening the thruster and fixture mounting bolts (if needed); checking the setup
parameters; and inspecting, cleaning, lapping and re-torquing the stack. Regional training
programs are also available from Dukane, as is an extensive series of training workshops at
the St. Charles facility.


What Amplitude is needed to weld my plastic components?
What exactly is Amplitude and why is it important? Amplitude is the peak-to-peak
movement, or expansion/contraction, of an ultrasonic tool stack. Each component can
multiply the amplitude that comes from the transducer, the amount of increase or decrease
is called "Gain". The total gain of the stack components determines the final amplitude at
the working face of the ultrasonic horn, where part contact is made. The ultrasonic tooling
stack includes the transducer, booster and horn. Some applications do not require a
booster and the horn is attached directly to the transducer. These are usually multi-head
automotive applications or packaging applications.

Some customers have tried to save money by not purchasing the correct booster for their
particular application. Making sure the ultrasonic tooling stack is producing enough
amplitude is one of the most important factors to successfully welding parts.

Yes, there may be a setting or two that can be adjusted in the ultrasonic welding system,
like adjusting the pressure, but that doesnt mean that the material at the joint area is
actually co-mingling. If parts are not welded properly, they probably won't pass inspection
or may even break apart in your hands. Worse yet is the possibility of your customer
returning parts due to poor quality. Insufficient amplitude is often evidenced by not only
weak welds but also incomplete welding where the melt around the interface is not
completely present. A weld detail, e.g., energy director, may show signs of embedding into
the mating surface instead of melting. If you have a weld time that is less than .1 seconds
and your process seems to produce erratic results, then possibly your amplitude is too high
and a reduction needs to be made.

A chart is included that shows some amplitude requirements of basic materials. Use the
example as a guide for your current resin and ultrasonic tooling stack to see if you have
enough amplitude for your application. Generally speaking, amorphous plastics require less
amplitude than semi-crystalline materials.