4 steps to a successful ultrasonic welding machines assembly

If you already own a complete ultrasonic metal welding machine. You must be interested in how it goes from a few iron pieces to an assembled welding system.

Although we don’t expect our customers to perform these assembly steps, understanding the assembly process can go a long way in helping you realize the potential of your ultrasonic welding machine.

Step 1 – Determine if your material is suitable for ultrasonic welding

First, check the materials to be ultrasonically welded. They must be cold metals, mainly copper, aluminum, nickel, gold, silver, etc. The maximum thickness should not exceed 5 mm. The welding area should not exceed 50 mm².

The ultrasonic parts must also be designed so that the ultrasonic energy can be efficiently transferred to the metal object to be welded.

Then it is time to consider your ultrasonic tooling options. The amplitude rod, transducer, weld head, and fixture options all need to be matched.

Step 2 – Choose the right ultrasonic welding equipment

Typically, 20khz ultrasonic metal welding equipment has a broader range of applications. Because it can handle a wider range of part sizes and is more suitable for cold metals, it is also ideal when a larger amplitude is required to weld metal. 2000w-5000w generators are available with a wide range of options for your practical application. Traditionally, the larger your parts and horns, the more power you need to run horns at full amplitude.

Our sales engineers can help you design your system to meet specific program requirements, such as process control and connection to the Myers system and the cooling needs of the welding process.

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Step 3 – Assemble and install the ultrasonic tool

Since the transducer alone cannot produce an amplitude sufficient to mechanically weld metal, your ultrasonic tool and application engineer will determine the gain factor required for the horn to match the amplitude requirements of the welded metal.

Next, you will need to assemble the transducer, amplitude rod, and horn, first making sure that all accessories’ surfaces and contact surfaces are clean and free of foreign matter. Screw the components together and apply some pressure to make them tight enough.

Once assembled, they can be easily installed into the welding system according to our operating manual. It is important to note that the precise alignment of the weld head and base is essential. You can use a vertical measuring tape or a horizontal measuring tool.

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Step 4 – Set the device parameters to start the test

We need to set the welding parameters corresponding to the size of the welding surface, such as air pressure, energy, etc. Then prevent the object from being welded from the middle of the base and align it precisely. After fixing the welded object placed underneath, step on the foot pedal to weld directly. 2-3 seconds later, check the welding quality and adjust the equipment parameters and parts as needed.

The above is the assembly steps of an ultrasonic metal welding machine. The article is universality, if this article is not enough to solve your targeted problems, you can contact us directly, we will provide you with separate professional guidance.

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