HYUSONIC FAQs
Here, you can find common questions from our customers, covering general topics such as logistics and orders, as well as questions related to ultrasonic plastic welding, ultrasonic metal welding, ultrasonic cutting, and other areas.
General Questions
1.What’s your MOQ?
Our products include ultrasonic welding machines, ultrasonic cutting machines, sealing machines, automatic welding machines, ultrasonic horns, ultrasonic blades, etc. There is no minimum order quantity, please purchase according to your needs.
2.Can we be your agent in our country or city ?
Of course. We are excited to expand our global operations and look forward to establishing a mutually beneficial partnership with you, driving shared success through collaboration.
3.How about your delivery time?
If you purchase a standard machine from our stock, it usually takes 1-2 weeks to deliver. If you require a custom special function or automated welding line, it usually takes 1-2 months to deliver.
5.How about the quality?
Our ultrasonic machines are derived from German cooperative technology. Our welder are able to maintain stable power output at high welding frequencies.
Q.Why does the machine whistle when welding?
- There are two possible reasons for whistling during welding: 1. The ultrasonic horn is not installed firmly. 2. The ultrasonic horn is damaged. You need to reinstall the horn and keep it tight. If it still doesn’t work, you need to remove the horn and check if there are any cracks on it.
Machine makes loud buzzing noise but no vibration
90% due to cracked piezoelectric ceramics in transducer. Test with impedance analyzer (should read 16-22Ω at 20kHz).
How to detect a failing ultrasonic generator?
Signs include: ① Output current fluctuation >±10% ② Abnormal frequency sweep waveform ③ Over 5% power loss vs. baseline.
When should I replace the converter (transducer)?
When: ① Resonance frequency shifts >±0.3kHz ② Insulation resistance <50MΩ ③ Visual cracks on casing.
How to detect a failing ultrasonic generator?
Signs include: ① Output current fluctuation >±10% ② Abnormal frequency sweep waveform ③ Over 5% power loss vs. baseline.
Can I weld 30% glass-filled nylon with standard equipment?
Requires: ① Hardened steel horn (HRC 58+) ② Amplitude boost to 65μm ③ 0.3mm chrome plating on contact surface.
Why does PVC produce toxic fumes during welding?
PVC decomposes at >180°C. Use pulse welding mode (0.1s on/0.05s off) and local exhaust.
How to synchronize multiple welders in production line?
Use master-slave configuration with phase locking (tolerance <2μs). Requires factory calibration.
What’s the difference between time-based and energy-based welding modes?
Time mode fixes duration (best for consistent parts); Energy mode stops at preset joule (ideal for variable thickness).
Parts shift position during welding cycle
① Increase pre-trigger force by 20% ② Add alignment pins to fixture ③ Use delayed trigger mode.
How to calculate required clamping force for 2mm thick copper sheets?
Force (N) = 150 x Weld Area (cm²). For 10x10mm joint: 150 x 1 = 1500N (1.5kN).
Weld interface shows incomplete bonding with "cold weld" appearance
Causes & Fixes:
Insufficient amplitude → Increase 10-15μm
Oxide layer contamination → Add argon shielding gas
Inadequate pressure → Boost clamping force by 20%
Micro-cracks observed in aluminum welds after cooling
Solutions:
Reduce cooling rate (post-weld annealing at 150°C for 30s)
Switch to linear amplitude profiling (ramp down last 0.2s)
Abnormal sparking at welding head during operation
Critical Checkpoints:
Grounding resistance (<0.1Ω)
Insulation breakdown in Litz wires (use 1000V megger test)
Titanium horn arcing (polish surface to Ra<0.8μm)
How often to replace titanium alloy horns in high-volume production?
Lifecycle:
Aluminum welding: 500,000 cycles
Steel welding: 200,000 cycles
Monitor surface wear depth (replace if >0.1mm)
White powder deposits on transducer – safe to clean?
Yes! Caused by titanium horn wear:
① Disconnect power
② Wipe with ethanol + lint-free cloth
③ Apply thin silicone grease (Dielectric Constant >2.5)
Can ultrasonic welding join copper to aluminum?
Limited application:
Only feasible with 0.5mm foil layers
Must add 5μm nickel interlayer
Requires 80μm amplitude + 300°C preheat
Why does galvanized steel produce toxic fumes during welding?
Zinc vaporization above 420°C:
Use pulsed mode (0.3s on / 0.1s off)
Install fume extractor with HEPA+activated carbon
How to prevent workpiece sticking to the sonotrode?
Coat horn with TiAlN (厚度3-5μm)
Implement 0.05s post-weld retraction delay
Ultrasonic welding of battery tab stacks (Ni+Al+Cu)?
Critical Parameters:
Stack height ≤0.8mm
Amplitude gradient mode (Start: 25μm → End: 45μm)
Pressure profiling (Ramp up 20N/ms)
Why does my food cutter leave ragged edges on soft cheeses?
Increase amplitude to 50μm and reduce feed speed by 30%. Pre-chill blades to -5°C for clean cuts.
Q.Why can't ultrasonic food cutter cut high-temperature foods?
- When the ultrasonic food cutting machine cuts high-temperature food, the temperature of the ultrasonic knife will rise. The temperature rise will reduce the transmission frequency of ultrasonic waves in the metal, and the machine will alarm when the power reaches the limit.
FDA-approved materials for food-grade ultrasonic blades?
Use 316L stainless steel with electropolishing (Ra <0.4μm) or titanium Grade 23 with DLC coating.
How to sanitize blades between meat and vegetable processing?
CIP protocol: 70°C 3% H₂O₂ rinse → deionized water flush → 10s ultrasonic cleaning at 40kHz.
Can I cut frozen products at -18°C?
Requires cryogenic blade adapters (-30°C rating) and 25% amplitude boost. Max thickness: 150mm.
"Amplitude Drift" error during thick rubber cutting
Compensate with closed-loop control:
① Install load cell feedback
② Set PID parameters: P=2.5, I=0.8, D=1.2
Inconsistent pattern definition on polyester fabrics
Solutions:
Preheat fabric to 70°C with IR array
Increase horn contact pressure by 0.2N/mm²
Use dual-frequency mode (28kHz + 35kHz)
Proper storage for inactive blades
Clean with anhydrous ethanol
Coat with food-grade silicone (cutting edge only)
Store vertically in ESD-safe container