The Pennsylvania State University at Erie The Behrend College Ultrasonic/Vibration/Hot Gas Welding Presented by: Kevin Himes Marty Timm James Scott.

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Presentation transcript:

The Pennsylvania State University at Erie The Behrend College Ultrasonic/Vibration/Hot Gas Welding Presented by: Kevin Himes Marty Timm James Scott

Ultrasonic Welding Basic Purpose & Process Produce hermetic bonded joints Mechanical movement High frequency sound energy Oscillating horn 20 to 40 KHz Very quick cycles

Ultrasonic Welding Equipment

Ultrasonic Welding Types of Joining Welding Staking Inserting Swaging Spot Welding Slitting Textile/Film Sealing

Ultrasonic Welding Welding Parameters Weld – by – Time Weld – by – Energy Weld – by Collapse Distance

Ultrasonic Welding

Appliances Automotive Electrical Medical Packaging Toys

Ultrasonic Welding Materials Most Thermoplastics Stiffer easier to weld Higher melt temperatures require more energy Similar molecular structures Crystalline only weldable to themselves

Ultrasonic Welding Advantages Energy efficiency High productivity with low costs Ease of automated assembly lines Fast joining times

Ultrasonic Welding Disadvantages Limited component length of 250mm Bondable materials

Vibration Welding Basic Purpose and Process Produce strong, pressure-tight welds Rubbed together under pressure Suitable frequency and amplitude Hz 1-4 MPa pressure 1-5 mm amplitude Rapid cycles

Vibration Welding

Materials Both amorphous and semicrystalline Injection molded, extruded, blow molded, thermoformed, or stamped Crystalline thermoplastics Acetal, polyethylene, nylons and polypropylene

Vibration Welding Typical Applications Automotive Aerospace Appliance Medical Electrical / Electronic Recreational

Vibration Welding Advantages Large complex linear joints Applicable to most polymers High production rates Number of components simultaneously Simplicity of tooling

Vibration Welding Disadvantages Materials with similar melt temps Limited part geometry

Vibration Welding New advancements Ability to vary pressure during cycle Development of equipment or orbital welding

Hot Gas Welding Process Hot gas Two thermoplastic materials Filter rod

Hot Gas Welding Equipment Heater unit Nozzle Remote air compressor or integral blower

Hot Gas Welding Two main types Speed Welding Round Nozzle Welding

Hot Gas Welding

Advantages Cheap Simple equipment Simple Operation

Hot Gas Welding Disadvantages Limited Materials Lower Strength