Ultrasonic welding is one among the staple process and techniques currently employed by different industries within the world. The products which will be produced and made through this process are quite extensive. From metal roofing to car roofing, there numerous applications of this process. Since this process is economical and is apt for production of certain products, manufacturing companies greatly depend upon it. Due to this process’ effectiveness and efficiency, many industries still believe it when manufacturing certain materials and products.
In the book “Handbook of Plastics Joining: A Practical Guide” authored by Michael J. Troughton, the method of ultrasonic welding was thoroughly discussed. consistent with the book, this process is one among the foremost widely used welding methods for joining thermoplastics, uses ultrasonic energy at high frequencies (20-40 kHz) to supply low amplitude (1-25 µm) mechanical vibrations. The vibrations generate heat at the joint interface of the parts being welded, leading to melting of the thermoplastic materials and weld formation after cooling. Ultrasonic welding is that the fastest known welding technique, with weld times typically between 0.1 and 1.0 seconds.” Throughton added that apart from welding, this technique’s “ultrasonic energy is usually used for processes like inserting metal parts into plastic or reforming thermoplastic parts to mechanically fasten components made up of dissimilar materials. When a thermoplastic material is subjected to ultrasonic vibrations, sinusoidal standing waves are generated within the material.”
With the seemingly simple yet very effective use of this system, many industries are hooked in to it. Today, many of the items you see around you were manufactured with the assistance of such industrial processing technique. However, this doesn’t mean that this system and process only provide heap of benefits. A bit like the other industrial technique, this sort of welding also features a justifiable share of disadvantages.
There are countless advantages and benefits related to this sort of commercial welding, but it also has its down sides. In reference to this, it’s essential and important to tackle the pros and cons of this process. Below are a number of the benefits and drawbacks of using this process for industrial purposes.
• When using for mechanical fastening, welding through the utilization of ultrasonic energy is efficient on any materials. It’s also provide low-cost service, which is useful when creating prototypes and products of small batches. However, for multiple small components, this system may cost more because it requires more intensive labor. Also, it’s going to loosen when the merchandise is employed.
• This technique is additionally effective in adhesive bonding. Adhesives could also be used for materials that aren’t compatible for welding. The technique also promises low cost in producing small batches of products and materials. Although it’s effective in adhesive bonding, it’s going to take longer time to hitch the parts and should got to be clamped until they bond. There’s also some safety risks involved because the process may emit harmful gases.
• For low frequency vibration molding, welding via ultrasonic energy is additionally effective. The technique has the capacity for larger components aside from ultrasonic. However, it might require relatively complex equipment, and should only be suitable for axis-symmetric welds.
• This sort of welding is additionally used for hotplate welding. It’s capacity of larger components aside from ultrasonic. It’s also good for skinny, conductive materials like laminated metal-plastic foils.
Despite the amount of disadvantages of this sort of commercial welding, including metal roofing, automotive roofing welding, it’s considered one among the foremost effective, practical, cost-efficient, and fastest techniques for welding dissimilar materials. Due to this, many industrial companies provide such industrial technique to consumer products companies that need faster turnaround and more reliable welding technique.