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What welding problems are prone to occur when using ultrasonic spot welders?

Ultrasonic welding is currently a new type of welding method. Compared with the traditional welding method, the ultrasonic spot welding machine has the advantages of fast speed, high precision and high strength. But pay attention to use and operation during use, otherwise welding quality problems will easily occur. What welding problems are prone to occur when using ultrasonic spot welders?

1. Inconsistent welding effect

The main reasons for this situation are: incorrect additive ratio, poor material quality, and injection mold grinding. The way to solve this problem is to correctly determine the proportion of additives, use good materials, and check the injection mold with an ultrasonic spot welding machine before welding.

2. Non-welded surface damage

The reason for this phenomenon is that the concentrated damage and lifting of ultrasonic waves do not coincide with the contact surface between the plastic and the welded joint. The solution to this problem is to repair the welded joint at the corresponding position to avoid gaps and repair the contact surface so that the plastic and the welded joint overlap.

3. Insufficient welding

The main reason is that the input energy of plastic parts is too small. The methods to solve this problem are: increase the welding time or air pressure, increase the amplitude, use a high-power auxiliary rod, and use a high-power hammer.

Fourth, excessive integration

When the input energy of the plastic part is too large, the excessive welding can be solved by reducing the welding time or pressure, reducing the amplitude, using a low-power secondary rod, and using a low-power welding machine.

5. Starting and breaking of plastic parts

The reason is that the plastic part itself is fragile and the amplitude of the ultrasonic wave is too large. The solution is to thicken the plastic parts, reduce the ultrasonic amplitude, and use a low-power secondary rod.

6. Plastic part perforation

The reason for this phenomenon is that the welding time is too long, the ultrasonic amplitude is too small, and the ultrasonic damage is concentrated. The solution to this problem is to shorten the welding time, increase the welding amplitude, use a high-power welding machine, and thicken the plastic parts. When there is a problem with welding, we must first find out where the problem is, find out the cause of the problem, and then take targeted measures to deal with it, and do more with less.

The above are the welding quality problems that are prone to occur during the use of ultrasonic spot welding machines. If there is any problem, corresponding treatment measures should be taken according to the specific situation to improve the welding situation.