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Ultrasonic, Vibration, and Hot Gas Welding Techniques at Penn State Erie

Learn about ultrasonic, vibration, and hot gas welding processes used to create bonded joints efficiently at Penn State Erie. Explore equipment, materials, applications, advantages, and disadvantages of these welding techniques.

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Ultrasonic, Vibration, and Hot Gas Welding Techniques at Penn State Erie

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  1. Ultrasonic/Vibration/Hot Gas Welding Presented by: Kevin Himes Marty Timm James Scott The Pennsylvania State University at Erie The Behrend College

  2. Ultrasonic Welding • Basic Purpose & Process • Produce hermetic bonded joints • Mechanical movement • High frequency sound energy • Oscillating horn • 20 to 40 KHz • Very quick cycles

  3. Ultrasonic Welding • Equipment

  4. Ultrasonic Welding • Types of Joining • Welding • Staking • Inserting • Swaging • Spot Welding • Slitting • Textile/Film Sealing

  5. Ultrasonic Welding • Welding Parameters • Weld – by – Time • Weld – by – Energy • Weld – by Collapse Distance

  6. Ultrasonic Welding

  7. Ultrasonic Welding

  8. Ultrasonic Welding • Appliances • Automotive • Electrical • Medical • Packaging • Toys

  9. Ultrasonic Welding • Materials • Most Thermoplastics • Stiffer easier to weld • Higher melt temperatures require more energy • Similar molecular structures • Crystalline only weldable to themselves

  10. Ultrasonic Welding • Advantages • Energy efficiency • High productivity with low costs • Ease of automated assembly lines • Fast joining times

  11. Ultrasonic Welding • Disadvantages • Limited component length of 250mm • Bondable materials

  12. Vibration Welding • Basic Purpose and Process • Produce strong, pressure-tight welds • Rubbed together under pressure • Suitable frequency and amplitude • 100-500 Hz • 1-4 MPa pressure • 1-5 mm amplitude • Rapid cycles

  13. Vibration Welding

  14. Vibration Welding • Materials • Both amorphous and semicrystalline • Injection molded, extruded, blow molded, thermoformed, or stamped • Crystalline thermoplastics • Acetal, polyethylene, nylons and polypropylene

  15. Vibration Welding • Typical Applications • Automotive • Aerospace • Appliance • Medical • Electrical / Electronic • Recreational

  16. Vibration Welding • Advantages • Large complex linear joints • Applicable to most polymers • High production rates • Number of components simultaneously • Simplicity of tooling

  17. Vibration Welding • Disadvantages • Materials with similar melt temps • Limited part geometry

  18. Vibration Welding • New advancements • Ability to vary pressure during cycle • Development of equipment or orbital welding

  19. Hot Gas Welding • Process • Hot gas • Two thermoplastic materials • Filter rod

  20. Hot Gas Welding • Equipment • Heater unit • Nozzle • Remote air compressor or integral blower

  21. Hot Gas Welding • Two main types • Speed Welding • Round Nozzle Welding

  22. Hot Gas Welding

  23. Hot Gas Welding • Advantages • Cheap • Simple equipment • Simple Operation

  24. Hot Gas Welding • Disadvantages • Limited Materials • Lower Strength

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