Ultrasonic Welding Trouble Shooting Guide - 6 Pages

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Ultrasonic Welding Trouble Shooting Guide

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Ultrasonic Welding Trouble Shooting Guide PROBLEM PROBABLE CAUSES Too much energy into the part. Reduce pressure, trigger force and/or down speed Weld time too long. Reduce weld time/energy/ collapse. Change to lower ratio booster to reduce amplitude. Digitally reduce the amplitude %. Use Amplitude Profiling. Reduce down speed. Change to lower gain horn if lowest booster is already in use. Absolute distance too high. Recalibrate absolute distance and adjust. Insufficient energy into the part. Increase pressure, trigger, and/or down speed. Insufficient weld time. Increase weld time/energy/ collapse. Insufficient amplitude. Use higher ratio booster to increase amplitude, if horn allows. Change to higher gain horn if highest booster is already in use. Energy loss into fixture. If fixture is urethane, change fixture to rigid material such as aluminum, stainless steel. Evaluate part fit in fixture. Presence of mold release. Eliminate use or clean parts after molding. Increase absolute distance. Moisture absorption by hygroscopic material. Warped part(s). Check part dimensions and flatness Check molding conditions. Use higher trigger pressure. Non-uniform horn face amplitude. Have horn tested (and modified if needed) to establish uniformity. Lack of parallelism between horn, fixture and part. Insufficient support in the fixture. Shim fixture where necessary, or level adjustable plate. Check part dimensions/flatness. Check part fit with horn using carbon paper. Improve support in critical areas. Change to a rigid fixture. If large sections of urethane are deflecting, add rigid backup Non-uniform weld around the joint

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PROBABLE CAUSES Non-uniform weld around the joint (continued) Inconsistent energy director height. Correct mold to ensure uniform energy director height. Check molding conditions. Wall flexure. Add internal ribs to part. Increase wall thickness. Modify fixture to prevent outward flexure. Knock-out pin location in joint area. Move knock-out pin location from joint area. Make sure knock-out pin marks are flush with surface. Improper alignment. Check for part shifting during welding. Check alignment features in mating parts. Check for parallelism of horn, part, and/or fixture. Non-uniform horn...

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Drop in air line pressure. Raise compressor output pressure. Add surge tank with a check valve. Check air supply line capacity vs. number of welders supplied. Filler content too high. Reduce percentage of filler. Check molding conditions. Change type of filler, i.e., short- to long-glass fibers. Check molding conditions. Check mold design. Incorrect joint design. Redesign joint, check with Branson applications engineering. Improve part dimensions. Improve part tolerances. Check molding conditions and improve. Incompatible materials or resin grades or lots. Check Branson Technical...

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Check for loose tip. Reduce weld time. Cool horn with ambient or refrigerated air. Check coupling between horn and booster. Visually check for cracked horn. If horn is titanium, change to chrome-plated aluminum. Check part dimensions. Check fit of horn to part in fixture. Use polyethylene film between horn and part. Relieve horn. Use recessed lettering where possible. Aluminum oxide (from horn). Chrome-plate or clear anodized horn and/or fixture. Use polyethylene film between horn and part. Overwelding: control mode (time, energy, collapse or absolute distance, peak power, force) too high....

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PROBABLE CAUSES Misalignment of welded assembly (continued) Joint design improper dimension. Redimension parts. Part tolerance/poor molding. Tighten part tolerances. Check molding conditions. Reduce weld time/energy/pressure. Too much energy into the part. Reduce amplitude by changing to a lower gain booster, or utilize Amplitude Profiling. Reduce pressure and/or down speed. Reduce weld time/energy. Adjust Dynamic Trigger pressure. Investigate the use of alternate frequencies. Long weld time. Reduce weld time by adjusting amplitude and/or pressure. Adjust Dynamic Triggering pressure....

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Ultrasonic Welding Trouble Shooting Guide PROBLEM PROBABLE CAUSES Excessive amplitude. Reduce amplitude. Utilize Amplitude Profiling. Long weld time. Reduce weld time by increasing amplitude and/or pressure. Gate location. Check gate placement. Check molding conditions. Change shape of gate. Add stiffening ribs to the part. Increase thickness of material on the underside of the gate area. Horn type and/or placement. Thin wall section. Internal parts welding Branson Ultrasonics Corporation Address Weoiosid wkeoijsdon 41 Eagle Road, Danbury, CT 06813-1961 Address Weoiosid wkeoijsdon (203)...

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