Ultrasonic Welding: Plastic, Metal, Sealing & Cutting Guide

what is ultrasonic welding

Ultrasonic welding is a cold welding process that utilizes high-frequency ultrasonic vibrations to raise the temperature of materials, enabling molecular chains to move and reorganize for bonding.

Ultrasonic welding employs high-frequency vibrations to locally heat materials and uses mechanical pressure to facilitate molecular bonding. The temperature is typically maintained between the material’s glass transition temperature and melting point, avoiding macroscopic melting caused by external heating. Characterized by precision control, environmental sustainability, energy efficiency, and the absence of thermal damage, ultrasonic welding is classified as a cold welding process.

how ultrasonic welding works？

1. components of ultrasonic welding

To understand the working principle of ultrasonic welding, it is necessary to first understand the important components of ultrasonic welding. These components(ultrasonic welding system) include generator, transducer(convertor), booster, horn（sonotrodo）, and fixture(welding nest).

2. ultrasonic welding machine working principle

The working principle of an ultrasonic welding machine is a process of converting electrical energy into mechanical energy.

First, the ultrasonic generator (power supply) converts the mains frequency of 50/60 Hz into the resonant frequency of the ultrasonic transducer.
Next, the ultrasonic transducer converts electrical energy into ultrasonic waves through the piezoelectric effect of piezoelectric ceramic plates.
The transducer transmits the ultrasonic waves to the booster, which uses the high-frequency vibration of the ultrasonic waves to induce resonance in the horn, ultimately converting it into mechanical energy.
Finally, the welding horn uses the mechanical energy from high-frequency vibration to heat the joint of the workpiece and complete the welding.
This is the complete working principle of an ultrasonic welding machine.

3. ultrasonic welding principle

Usually, when we mention ultrasonic welding, the first thing that comes to mind is ultrasonic welding of plastics. Because these plastic products are very common in our daily lives. In addition to welding plastics, ultrasonic can also be used to weld non-ferrous metals, non-woven fabrics, cut food, cut rubber, non-woven fabrics, plastic films, and other composite materials.

The principles of ultrasonic welding vary depending on the application field. It is necessary to introduce these ultrasonic welding principles separately according to these different ultrasonic welding and cutting application fields.

The following are the common uses and welding principles of ultrasonic welding：

advantages of ultrasonic welding

1. High efficiency with fast welding/cutting speed, saving time and labor for various materials.

2. No additional adhesives or fasteners, eco-friendly with minimal material waste.

3. Strong, leak-proof joints/seams with consistent quality, ideal for durable products.

4. Versatile applications across plastics, metals, nonwovens, composites, rubber, and even food.

5. Energy efficiency with low power consumption compared to traditional methods.

6. Clean process without chemical residues, safe for food-grade and medical applications.

7. Precise control enables intricate designs and tight tolerances in delicate materials.

8. Cost-effective long-term due to low maintenance and high equipment durability.

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