How Ultrasonic Welding Works

Ultrasonic assembly utilizes an acoustic tool called a horn to transfer vibratory energy through the part to the joint area, where it is converted to heat through friction that melts the plastic. Ultrasonics can be used to join not only rigid thermoplastics, but fabrics and films as well. Branson ultrasonic welding equipment converts 50/60 Hz current to 15, 20, 30, or 40 kHz electrical energy through a solid-state power supply. This high frequency electrical energy is supplied to the converter that transforms it to mechanical motion at ultrasonic frequencies. The mechanical motion is then transmitted through an amplitude-modifying booster to the horn. The horn, an acoustic tool, transfers this vibratory energy directly to the parts being assembled. The main components of an ultrasonic system are the power supply, converter/booster/horn stack, part fixture, and a means of providing horn contact with the parts - usually an actuator. Four frequencies of ultrasonic equipment are available to accommodate your application requirements.