How are quality inspection and optimisation conducted following sampling with an ultrasonic plastic welding machine?
Apr 30, 2025
Destructive Testing
Weld strength must exceed 80% of base material strength.
Example: ABS weld strength ≥35 MPa (base material strength: 45 MPa).
Assess fusion layer thickness via metallurgical microscopy.
Standard fusion zone width = 1.5–2× material thickness.
Non-Destructive Testing
Conduct ultrasonic C-scanning to detect weld defects (sensitivity: 0.1 mm³), with defect rate ≤1%.
Perform seal integrity testing (ASTM F2096):
No leakage permitted under 0.1 MPa air pressure for 30 seconds.
Process Optimisation
For flash formation:
Reduce amplitude by 10% and extend dwell time by 20%.
For insufficient fusion:
Increase horn surface roughness to Ra 0.8 μm to enhance frictional heating.
