What is ultrasonic welding horn?
Ultrasonic horn stretches and shrinks in length during the welding process like a spring. For example, a 20 kHz horn is typically a one-half wavelength long resonant bar, whose molecules are constantly expanding and contracting 20,000 times per second. Consequently, the horn is continually under compression or tension.
What is the function of horn in ultrasonic welding?
The ultrasonic horn has three primary functions: 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.
What is a Branson horn?
Branson Ultrasonics, a business of Emerson Industrial Automation, manufactures a variety of superior ultrasonic horns and tooling. Standard horns listed in the catalog are compatible with most of today’s ultrasonic welding equipment.
How much does ultrasonic welding cost?
Ultrasonic welders cost anywhere from $18,000 to $45,000, depending on power capacity and bells and whistles, such as statistical process control packages. A basic 20-kilohertz, 2.5- to 3.5-kilowatt ultrasonic metal welding system can be acquired for around $30,000.
What is a welding horn?
A welding horn, also known as a sonotrode, is an acoustical tool that transfers the mechanical vibrations to the workpiece, and is custom-made to suit the requirements of the application.
How is ultrasonic horn gain calculated?
The normal length of a 20khz Aluminum Horn is between 5.1 to 4.8 inches. Gain of a ultrasonic horn is function of the mass above the nodal point to the mass below the nodal point. The gain of a Blade horn is the Input depth divided by the Output depth.
What is the difference between ultrasonic welding and vibration welding?
The vibration welding process vibrates one component relative to another in a linear side-to-side motion. The friction between the two objects generates the heat used for welding. Conversely, the ultrasonic welding process vibrates one component perpendicularly to another much like a jackhammer on pavement.
How does vibration welding work?
The vibration welding process uses rapid linear motion to create friction and heat at the joint interface of the parts to be mated. This process lasts until the right molten state is reached. The plastic then solidifies under clamping pressure and forms a permanent bond.