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

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

3. Ultrasonic Welding Equipment

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

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

6. Ultrasonic Welding

8. Appliances Automotive Electrical Medical Packaging Toys

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

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

11. Ultrasonic Welding Disadvantages Limited component length of 250mm Bondable materials

12. Vibration Welding Basic Purpose and Process Produce strong, pressure-tight welds Rubbed together under pressure Suitable frequency and amplitude 100-500 Hz 1-4 MPa pressure 1-5 mm amplitude Rapid cycles

13. Vibration Welding

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

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

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

17. Vibration Welding Disadvantages Materials with similar melt temps Limited part geometry

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

19. Hot Gas Welding Process Hot gas Two thermoplastic materials Filter rod

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

21. Hot Gas Welding Two main types Speed Welding Round Nozzle Welding

22. Hot Gas Welding

23. Advantages Cheap Simple equipment Simple Operation

24. Hot Gas Welding Disadvantages Limited Materials Lower Strength