how long the ultrasonic metal welder can work ,and Problems analysis

The service life of a welding head is determined by two key aspects: First, the material, and second, the process
Material: ultrasonic welding requires metal materials with good flexibility (small mechanical loss during the transmission of sound waves) good characteristics, so the most commonly used materials for aluminum and titanium alloys, but ultrasonic metal welding requires the welding head wear-resistant (requiring high hardness), making the choice of materials becomes more difficult, because hardness and toughness seem to be inherently opposing, which requires us to choose very high requirements of the material, we The selected high quality steel material can solve this contradiction relatively well, so that the effective life of the weld head as much as possible.
Processes: including processing technology and subsequent treatment process, processing technology has been described in detail earlier, subsequent treatment includes heat treatment and parameter adjustment, based on our choice of materials, we have an original heat treatment process to ensure; after each weld head is made, the parameters are individually measured and adjusted to ensure the production.

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Heat generation
Welding head in the work will have a certain heat phenomenon, which is due to the mechanical loss of the material itself and the welding piece heat conduction. The standard for judging whether the heat of the welding head is normal without load (i.e., not in contact with the workpiece), continuous emission of ultrasound for more than half an hour, the temperature can not exceed 50-70 ℃, such as heat is very strong, proving that the welding head has been damaged or the material is not qualified and needs to be replaced.
Whistling
When the welding head work whistling, the following reasons should be analyzed: ① whether the installation screws have been loosened
② whether the weld head has cracks
③ Whether the weld head is in contact with an object that should not be in contact.
Overload
When the generator issues an overload alarm, the following steps should be followed to check.
① If the no-load test is normal, if the operating current is normal, the weld head may be touching an object that should not be touched or there is a malfunction in the parameter adjustment between the weld head and the solder holder.
② When the no-load test is not normal, you should first observe whether the weld head is cracked and firmly mounted, then remove the weld head and conduct the no-load test again to rule out whether there is a problem with the transducer+variable rod, and proceed step by step to exclude. After ruling out the possibility that the transducer + amplitude change rod is faulty, the new weld head will be removed and replaced to judge.
③ Sometimes there will be no-load test is normal, but can not work properly, it is possible that the solder head and other internal changes in the original sound energy, resulting in poor transmission of sound energy, here is a relatively simple method of judgment: hand touch method. Normal work of the welding head or variable amplitude rod surface work amplitude is very uniform, hand touch is velvety smooth, when the sound energy transfer is not smooth, hand touch will have bubbles or burr feeling, then we must use the exclusion method to exclude the problem components. When the generator is not normal, it can also produce the same situation, because normally the input waveform of the detection transducer should be smooth sine wave, when the sine wave has a spike or abnormal waveform can also produce this phenomenon, then you can use another whole branch of the sound energy components to replace to discriminate.

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