Archives 4月 2021

What is ultrasonic handheld spot welding

Ultrasonic Spot Welding

The ultrasonic spot welder belongs to the category of ultrasonic welding, where two materials, metal or plastic, are welded together using high-frequency vibrations generated by ultrasound. For thermoformed parts without assembly contours or features where geometry and physical conditions preclude the possibility of standard welding operations, ultrasonic spot welding is relatively more suitable for processing.

Spot welding can be performed on soft plastic sheets such as ABS, polyethylene, polypropylene, and PVC with ultrasonic power spot welding. Specially designed projection heads are used to enhance weld strength and appearance. Ultrasonic spot welding replaces adhesives, rivets, staples, and other mechanical fasteners. The process is used to assemble trailer bodies, automotive defroster pipes, furniture, and other large thermoplastic parts. Many welds can be performed simultaneously using portable handheld tools as well as multi-head automation systems.

The principle of spot welding

Ultrasound is a mechanical vibration, similar to that produced by a musical instrument. These vibrations are called ultrasonic waves because they have a frequency higher than the hearing of the human ear (greater than 16 kHz). In an acoustic assembly, these pressure waves are generated by a generator. This sends an alternating current of the same frequency as the transducer (or transducer). The transducer, made of piezoelectric ceramic, then converts this energy into mechanical vibrations. The mechanical vibrations then create thermal friction, which excites the material’s molecules being welded to start moving. The ultrasonic energy melts the contact points between the two parts, thus creating a joint that allows the parts to be bonded quickly.

The spot welder is suitable for those components that do not require the entire welding path to be welded simultaneously, is inherently lightweight and easy to use, and can be used in outdoor scenarios. Spot welders are highly versatile, flexible, and cost-effective, and therefore remain highly competitive in various welding applications.

Working Process of Ultrasonic Spot Welding

Working Process of Ultrasonic Spot Welding

The advantages of ultrasonic spot welding

  • Welding process: Ultrasonic welding is monitored by time, energy, power, and height limits, and the entire welding process is detected in real-time, maximizing the efficiency of the entire welding process and minimizing the energy consumed in production.
  • Cost-saving and environmental protection: The whole welding process is clean and pollution-free because no harmful solvents or binders are used in the welding process, and no damage is done to the product itself, avoiding some of the problems of traditional welding and bonding processes and saving welding costs. The technology does not require a high level of maintenance due to its complete electrical characteristics.
  • Speed: Typical welding cycles are within 0.5 seconds, which is faster compared to other welding methods. This welding technique is much faster than traditional adhesives or solvents. The cooling time is speedy, and the workpiece does not have to be left in the tool for long periods of time to dry or cure the welded joint.
  • Easy to use: The general ultrasonic spot welding machine or spot welding gun equipment is a small machine, which is relatively light to operate and does not require high manual skills. Easy to collect after use, does not take up a lot of space. The ergonomic and lightweight handheld probe reduces operator fatigue. The lightweight system with an integrated handle makes the unit easy to move around the factory.
  • High welding accuracy: High precision thrust control and highly accurate weld depth control guarantee overall weld quality and avoid unsound welds—guaranteed certain welding quality to avoid material blackening or burning.

The composition of ultrasonic handheld spot welder

The ultrasonic handheld spot welder equipment includes a flow control valve, transducer, ultrasonic generator, and welding head. Compared with ordinary welding equipment, the spot welder is more lightweight and suitable for welding jobs that require transfer scenarios.

An ultrasonic generator (power supply)

The ultrasonic generator converts the 110VAC or 220VAC electrical supply current into a high frequency, high voltage electrical signal.

An ultrasonic converter (transducer)

The ultrasonic converter utilizes the high-frequency electrical signal from the generator and converts it into linear, mechanical movement. This conversion occurs through the use of piezoelectric ceramic disks that expand when a voltage is applied.

An ultrasonic booster

The ultrasonic booster is a tuned component that mechanically adjusts the amount of linear vibratory movement from the converter to the required level for the specific application to produce optimal welding performance. The booster also provides a safe, non-vibrating location to clamp onto the welding tools.

An ultrasonic welding tool (horn/sonotrode)

The ultrasonic welding horn is a custom-made tool engineered to vibrate at a specific frequency. These tools are painstakingly designed using computer modeling technology for optimum performance and longevity. Ultrasonic tools must be tuned to match the frequency of the system. This tuning procedure requires consideration of the horn’s mass, length, and geometry.

Ultrasonic Spot Welding

Ultrasonic Spot Welding

The advantages of ultrasonic dip soldering device

ultrasonic dip soldering device

Ultrasonic dip soldering is the process of coating the surface of a part with molten tin by immersing the region in a tin bath containing the molten tin. Tin plating enables the piece to maintain good corrosion resistance, flexibility, and solderability. Ultrasonic dip soldering involves heating the tin metal by ultrasonic waves to melt the tin. The part is then dipped into the molten tin bath, and the surface of the part is soldered with a layer of tin through the ultrasonic cavitation effect and high-frequency vibration. After the ultrasonic dip soldering process, the components can be soldered more firmly than traditional soldering techniques.

The ultrasonic dip welding process can also be used for welding metals and alloys such as dip, aluminum, and magnesium. Ultrasonic dip welding has the characteristics of faster welding speed and more environmentally friendly. The most important feature of ultrasonic dip welding compared to other dip welding is the different method of removing the oxide film. Ultrasonic dip welding does not use any solder.

Shortcomings of conventional dip soldering

Poor soldering effect

In the traditional dip soldering process, there is oxidation in the parts, making it easy to have difficulty in soldering. In addition, oxides tend to form in the solder, so it needs to be cleaned up in time to get a better soldering result.

Easy component damage

The dip soldering process is easy to cause damage to components, so that PCB deformation, which is due to the same solder, PCB contact surface is wide, long, easy to lead to PCB board temperature is too high. The small volume of the printed circuit board and quality requirements are not very high single-board available traditional dip soldering.

The small scope of use

Conventional dip soldering technology is complex to solder parts made of glass, ceramics, and other materials, and additional processing must be performed. This, to a certain extent, also causes an increase in processing costs and processing difficulties.

Advantages of ultrasonic dip soldering

Environmentally friendly

Conventional metal soldering usually involves the use of fluxes. The main components of change are rosin, organic solvents, natural resins and their derivatives or synthetic resins, organic acid activators, anti-corrosion agents, oscillations, and film-forming agents. If in a situation containing high flux concentrations, its smell is inhaled by the body, there will be headaches, drowsiness. This can hurt both the human body and the environment. At the same time, the use of flux may cause problems with soldering, resulting in poor soldering quality.

Ultrasonic dip soldering is safe and environmentally friendly and does not require the use of harmful compounds such as substances that remove oxide film. No flux is used for dip soldering. There is no need for emission facilities or wastewater treatment facilities to remove harmful gases generated by flux, so no harmful chemicals are generated for the environment or human beings.

Cost-saving

There is no need for a pretreatment and washing process before performing ultrasonic dip soldering, which saves production costs and expenses, simplifies the soldering and dipping process, and improves production efficiency. Flux-related processes are not required, so equipment costs and production costs are reduced. Also, because no flux-related processes are required, the soldering process is simple (high soldering productivity).

Support for new application development

Ultrasonic dip welding can successfully use weld materials difficult to weld by conventional weldings, such as glass and ceramics. Suitable for solar cell glass, semiconductors, ceramic heaters, and dissimilar materials (Al-Cu, Al glass, Al ceramics).

Direct processing

Conventional dip soldering may require pre-processing, such as melting the tin metal in advance before it can be poured into the tin pot. Ultrasonic dip soldering, on the other hand, heats the tin directly and does not require pretreatment. In addition, the part can be dipped now into the pot and tinned directly. In contrast, conventional tin plating techniques need the details to be treated with oxides in advance; otherwise, successful tin plating may be intricate.

ultrasonic dip soldering

ultrasonic dip soldering

Ultrasonic dip soldering device

Ultrasonic enamel dipping equipment works by high-frequency vibrations of ultrasonic waves. The whole dipping welding is more efficient and capable of welding many different materials. Ultrasonic enamel dip equipment can also be used to weld with other welding alloys (also similar to a heated work cell where the working fluid has been replaced by molten solder). Ultrasonic waves and heat are passed through the working solder into the immersion vessel.

The technology of ultrasonic soldering

ultrasonic soldering

Ultrasonic soldering is a virtually flux-free soldering process that uses ultrasonic energy without chemical solder materials. It can be achieved with difficult-to-solder metals such as glass, ceramics, and composites and cannot be soldered using conventional devices. Ultrasonic soldering as a flux-free soldering process is increasingly used in the soldering of metals and ceramics, from solar photovoltaic cells and medical shape memory alloys to specialized electronics and sensor packages.

Ultrasonic soldering is a virtually flux-free soldering process that uses ultrasonic energy without chemical solder materials. It can be achieved with difficult-to-solder metals such as glass, ceramics, and composites and cannot be soldered using conventional devices. Ultrasonic soldering as a flux-free soldering process is increasingly used in the soldering of metals and ceramics, from solar photovoltaic cells and medical shape memory alloys to specialized electronics and sensor packages.

Ultrasonic solder equipment

Ultrasonic soldering uses an ultrasonic soldering iron or ultrasonic dip soldering equipment as described above. In these devices, piezoelectric crystals generate high frequency (20 – 60 kHz) sound waves in the molten solder layer or batch to mechanically destroy the oxides formed on the molten solder surface. The tip of the ultrasonic soldering iron is also connected to the heating element to prevent deterioration of the piezoelectric element, which will thermally isolate the piezoelectric crystal.

Ultrasonic soldering irons

Ultrasonic soldering irons generate heat when mechanically oscillating at frequencies of 20 – 60 kHz (up to 450°C). This soldering head melts the solder metal when acoustic vibrations are induced in the molten solder pool. The vibration and cavitation in the molten solder then wet the solder and adheres to many metal surfaces. The acoustic energy generated by the soldering tip works through the cavitation of the molten solder, which mechanically destroys the solder layer itself and the oxide layer on the surface of the metal being joined.
Conventional soldering irons do not have the help of ultrasonic energy to destroy the oxide layer on the solder and metal surfaces, leading to poor soldering during the soldering process. In addition, conventional soldering irons require flux in the soldering process, which can also affect the effectiveness of the soldering.

ultrasonic soldering iron

ultrasonic soldering iron

Ultrasonic dip soldering equipment

The cavitation produced by ultrasonic dip welding is very effective in destroying oxides on many metals. Still, it is ineffective when welding to ceramics and glass, which are themselves oxides or other non-metallic compounds because they are the base and therefore cannot destroy the material. In direct soldering to glass and ceramics, it is necessary to modify the filler metals for ultrasonic welding with active elements such as In, Ti, Hf, Zr, and rare earth elements (Ce, La, and Lu). The solders alloyed with these elements are called “active solders” because they act directly on the glass and ceramic surfaces to form a bond.

Glass and ceramics are inherently oxidized, making them difficult to join with conventional soldering devices. The cavity effect of ultrasound produces a cavity that absorbs oxygen when collapse while releasing heat energy. It is believed that this energy can be effectively used to form covalent bonds on the surface of the glass, etc., using oxygen absorbed by metallic elements that are highly oxyphilic in the molten state as a carrier. Under the vibration of ultrasonic waves, the molten solder gets thoroughly stirred, the tin at the solder interface absorbs oxygen more efficiently and may form a stronger covalent bond. Moreover, its geometric properties, chemical properties, and bond strength are no less than those of ordinary solder.

Ultrasonic dip soldering equipment

Ultrasonic dip soldering equipment

Summary

The use of ultrasonic soldering is expanding because it is clean and flux-free and incorporates reactive solder designated for joining components where corrosive fluxes may trap or disrupt operations or contaminate clean production environments dissimilar materials, metals, ceramics, glass, etc., are present for incorporation. The active solder’s incipient oxide needs to be destroyed and well-suited for ultrasonic agitation to adhere effectively to the surface. In applications with small or narrow solder joint areas, soldering with 1 – 10 mm soldering iron tips is very effective because the molten metal is small and can be effectively stirred by the 1 – 10 mm iron.

 

Why choose ultrasonic welding seam technology to weld non-woven products

ultrasonic seamless sewing machine

Disposable nonwovens are being used in a wide range of applications, whether packaged sterile surgical single-pack kits or personal protective equipment such as surgical caps and N95 masks, overalls and foot covers, disposable nonwovens provide an effective and inexpensive barrier against microorganisms and contamination. Its versatility extends to many other products, including hygienic and absorbent products, from shields and pads to diapers, undergarments, and disposable filters. All of these products mentioned above are made by seamless welding of nonwoven materials.

Disposable non-woven fabrics

Disposable non-woven fabrics

Ultrasonic seamless welding technology has played a vital role in promoting the rapid growth of the number of non-woven products and promoting its growth in this market area. Similar to the ultrasonic technology used for welding complex plastic parts, the ultrasonic welding technology transmits high-frequency mechanical vibration through the thermoplastic material to generate frictional heat to melt the seam surface of the non-woven fabric, thereby quickly bonding the non-woven fabric Together. Ultrasonic seamless welding machine technology has the following advantages:

ultrasonic seamless sewing machine

ultrasonic seamless sewing machine

Low consumption

Due to the speed, reliability, and energy efficiency of ultrasonic welding machines for slitting and stitching, manufacturers of non-woven products continue to convert older and energy-intensive cutting and stitching equipment (such as hot knives) to ultrasonic. The ultrasonic welder consumes power only when actually cutting or bonding. Because it generates heat immediately through high-frequency vibration, the hot knife can be preheated without additional energy consumption. There is no need to maintain it at a proper working temperature.

High speed

When ultrasonic welding is used to form seams or laminates, it is also swift, completing a single bond in a fraction of a second. It can also quickly continuous bond seams and is suitable for everything from disposable medical suits, surgical masks, and face masks to disposable hygiene products, diapers, nightgowns, filter media, etc. The fast, strong, and repeatable bond maintains the same strength as the parent material. Realize rapid production with minimal energy consumption, thereby reducing the cost of disposable absorbents and infection control products.

Good sewing effect

Compared with sewing, ultrasonic waves can form high-strength, high-integrity seams without stitches and do not need to create mechanical holes in the fabric containing and hide microorganisms or contaminants. It also eliminates the need for adhesives, including increased application workload, the increased time required for set-up and drying, and increased exposure to chemical pollutants. Ultrasonic seams can be used as soon as they are produced.

Small weld

Although traditional sewing machines have been and will always be common in clothing factories worldwide, in many sportswear (including sportswear and outdoor clothing) areas, ultrasonic welding has proven to be a better choice. On a traditional sewing machine, the needle pierces the hole in the fabric, weakening the structure of the fabric, and the overlap of the material at the seam creates thick stitching, which is heavy, restricts movement, wastes, and increases The weight of the garment—many negative factors in the sportswear market. Ultrasonic sewing machines can create such small welds that they must be supported by seam sealing tapes. Ultrasonic stitching is also beneficial in the production of many products. Because of the formation of impermeable seams, clothing worn in contaminated environments (such as medical or scientific fields) can protect people from harm. This impermeable seam also facilitates the production of sails, parachutes, and any other textile materials that must withstand and withstand strong winds.

Reduce waste

Ultrasonic seamless welding technology reduces waste in the production process. Because in the traditional sewing process, needle breakage often occurs, which causes a lot of garbage. And because there is no thread in ultrasonically welded clothing, the line will not deteriorate over time, and a large amount of material and waste can also be reduced. Simultaneously, this is very beneficial to the environment, making ultrasonic welding technology a “green” technology. When connecting non-woven fabrics, there is no need for any solvents or adhesives. The difference between ultrasonic sealing and thermal bonding is that due to ultrasonic energy to generate heat in the fiber, fiber degradation is minimized. In thermal bonding, heat energy is applied to the threads to melt them and avoid burrs.

 

The basics of ultrasonic handheld spot welding technology

spot welding machine

Ultrasonic handheld spot welding joins two thermoplastic parts at localized points without a preformed hole or energy director. It produces a solid structural weld and is especially suitable for large parts or parts with complicated geometry or hard-to-reach joining surfaces.  The horn has a pilot tip in spot welding, which melts through the top part and into the bottom portion to a predetermined depth when ultrasonic vibrations are applied. When vibrations cease, the melt from both parts flows together, forming a weld with the top side having a raised ring produced by the welding tip. The bottom layer of a spot welding joint has a smooth appearance. Spot welding can be performed with hand-held guns, single- or double-headed bench welders.

Common problems of traditional welding

  • High-temperature welding is easy to cause damage to the welding surface and even deform the product in severe cases.
  • The welding equipment is large, not easy to handle by hand, and unable to complete complex procedures.
  • The welding mode is too single, the welding material is restricted, and the welding head cannot be replaced at will.
  • Adhesives and fluxes are used for welding, the welding pollution is severe, and the welding strength is not high.
  • Adhesives, studs, or other mechanical fixation are used when welding, which is inefficient and costly.

The technology of ultrasonic spot welding

When ultrasonic waves act on the surface of thermoplastic plastics, high-frequency vibrations of tens of thousands of times per second are generated. The ultrasonic energy is transmitted to the welding area through the weldment, and local high temperatures will be generated. Due to the poor thermal conductivity of plastics, heat is concentrated in the welding area, causing the surface of the plastic to melt rapidly. After a certain pressure is applied, it is integrated.
A hand-held ultrasonic spot welding machine can be used for welding, riveting, spot welding of films, fabrics, thermoplastic products, and inlay and edge pressing processes between metal parts and plastic parts.

Advantages of ultrasonic spot welding

  • High stability: The digital electric box automatically tracks the resonant frequency and adjusts the output frequency to match the handheld device. Once a fault is found, it stops working and gives an alarm. Most of the ultrasonic welding can be completed within 0.1-0.5 seconds.
  • Energy-saving and environmental protection: The welding surface is not damaged or deformed, without scratches and adhesive residues, avoiding using a large number of fixtures, fluxes, and adhesives, reducing labor and reducing costs.
  • Reliable quality: Ultrasonic welding is solidified and formed, and the molecules are recombined to form a solid molecular chain. The strength of the weld can be close to the strength of the raw material.
  • Simple operation: Ultrasonic welding is very easy to realize automation. As long as the welding parameters are set, the welding can be carried out without preheating or cleaning.
  • Wide range of applications: Hand-held ultrasonic spot welding machines can be used for welding, riveting, spot welding of films, fabrics, and thermoplastic products, as well as inlay and edge pressing processes between metal and plastic parts.

How does HCSONIC ultrasonic spot welding works?

How do I start?

If you’re looking for this type of application for your current or new projects, you can head over to our project request to submit your designs. Our team of skilled mechanical engineers will assess your project and let you know if this technology is right for your project!

What is ultrasonic face mask welding machine

ultrasonic face mask welding machine

The ultrasonic face mask welding machine uses high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects are rubbed against each other to form a fusion between the molecular layers.

Some indentations can be seen everywhere on the mask, such as the edges, ear straps, and exhalation valve are all ultrasonically welded. As shown in the figure above, in the production process of masks, we can intuitively understand the welding of an all-plastic nose bridge, welding after hemming, breathing valve welding, multi-layer seam, and ear band welding. These are actually made by ultrasonic welding Finished.

ultrasonic face mask

When the ultrasonic wave acts on the thermoplastic plastic contact surface, it will generate tens of thousands of high-frequency vibrations per second. This kind of high-frequency vibration with a certain amplitude will transmit the ultrasonic energy to the welding area through the upper weldment. Because the welding area is two, The acoustic resistance at the welding interface is large so that the local high temperature will be generatAlsotion; due to the poor thermal conductivity of the plastic, it cannot be distributed in time for a while, and it gathers in the welding area, causing the contact surface of the two plastics to melt rap. Afterfter a certain pressure is applied, they are fused into one.

How ultrasonic welding machine works

welding process

When the ultrasonic stops, let the pressure continue for a few seconds to solidify and shape, thus forming a strong molecular chain, achieving the purpose of welding, and the welding strength can be close to the strength of the raw material. According to different welding methods, ultrasonic welding can be divided into embedded welding, riveting welding, spot welding, and forming.

Riveting_Nieten    Ultrasonic spot welding

Ultrasonic riveting                                         Ultrasonic spot welding

Ultrasonic welding uses 15 kHz-50kHz high-frequency vibration to melt and weld plastics.  The upper and lower parts are compressed. The ultrasonic vibration is transmitted to the joints of the upper and lower parts, causing alternating stress at the welding ribs, heating and melting the plastic through the friction between the molecules. The ultrasound stops, and the upper and lower parts continue to be pressed tightly until they are bonded together.

Composition of ultrasonic face mask welding machine

An ultrasonic generator (power supply)

The ultrasonic generator converts the 110VAC or 220VAC electrical supply current into a high frequency, high voltage electrical signal.

Ultrasonic power is divided into two kinds of simulation and numerical control; HCSONIC adopts numerical control power as more advantages.

  • Track the primary resonance
    During ultrasound operation, as the temperature, power, and load change, the frequency of resonance may shift, and the ultrasound generator can automatically follow this frequency shift.
  • Lock onto the primary resonance
    All ultrasonic systems have a primary resonance. Also, there will be secondary (spurious) resonances. When the power supply starts, it must lock onto the immediate resonance and ignore the secondary resonances.
  • Auto-adjust amplitude
    Most applications can be best controlled by controlling the output amplitude rather than the power. Amplitude should be regarded as the independent (input controlled) variable, and power should generally be considered the dependent (output resultant) variable.

ultrasonic power supply

An ultrasonic converter (transducer)

The ultrasonic transducer uses the high-frequency electrical signal from the ultrasonic generator and converts it into linear mechanical motion. This conversion is performed by using piezoelectric ceramic disks, which expand when a voltage is applied. The transducer used for ultrasonic rubber cutting is specially designed, and air can be introduced and discharged for cooling.

ultrasonic transducer

An ultrasonic booster

The ultrasonic booster is a tuned component that mechanically adjusts the amount of linear vibratory movement from the converter to the required level for the specific application to produce optimal welding performance. The booster also provides a safe, non-vibrating location to clamp onto the welding tools.

Ultrasonic booster and round flange

An ultrasonic welding tool (horn/sonotrode)

The ultrasonic welding horn is a custom-made tool engineered to vibrate at a specific frequency. These tools are painstakingly designed using computer modeling technology for optimum performance and longevity. Ultrasonic tools must be tuned to match the frequency of the system. This tuning procedure requires consideration of the horn’s mass, length, and geometry. HCSONIC provides various configurations; each configuration is designed for specific applications, strictly to ensure long-term good performance.

Ultrasonic face mask welding machine (20K) power: 2000W

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Ultrasonic face mask welding machine (15K) power: 2600W

Ultrasonic face mask ear loops welding machine (35K)

ultrasonic welding equipment

Mask welding machine welding video

Ultrasonic transducer customization

Simultaneously, we can also customize various ultrasonic transducers according to customer needs to meet the needs of production. For more information on the customization of ultrasonic transducers, please see.

Hangzhou Jiazhen Ultrasonic Technology focuses on developing, designing, and customizing power ultrasonic transducers and related materials. The company has experienced ultrasonic transducer design engineers and many years of experience in new product development and design and has passed the depth of research Institut. Ions The cooperation has formed a systematic and standardized technical system to ensure the quality of ultrasonic transducers/ultrasound probes in the development, testing, performance calibration and stability, and stability.

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Get the best prestress of the transducer.