Ultrasonic Booster

Ultrasonic welding machine is generally composed of ultrasonic generator, ultrasonic transducer, ultrasonic booster and supporting fixture, in which the horn mainly plays the role of energy transmission and amplification. The original amplitude of ultrasound is generally small, usually only a few microns, while the amplitude in actual processing applications requires dozens to hundreds of microns, so it is often necessary to magnify the amplitude of ultrasound through the horn. The effect of mechanical impedance can also be produced between amplitude and amplitude. Impedance matching between transducer and load can transfer ultrasonic energy from transducer to welding surface more effectively. The commonly used materials of the horn are aluminum alloy, low carbon steel, stainless steel and titanium alloy. Each material has its advantages and disadvantages. For example, although titanium alloy has high strength and good acoustic performance, it is more expensive; Aluminum alloy has low density and good acoustic performance, but it is easy to wear and fracture; Alloy steel has high strength and wear resistance, but its acoustic performance is relatively poor.

Aluminum alloy ultrasonic sonotrode has high node temperature rise in the welding process, so aluminum alloy booster is not suitable for large-scale and long-term production and processing, but it is more suitable for the welding of small batches and small parts. Compared with aluminum alloy ultrasonic horn, alloy steel ultrasonic horn booster has higher stiffness, elastic modulus and better wear resistance, so it is suitable for large batch and long-term processing environment. Titanium alloy ultrasonic welding booster is the most ideal material among all materials, but its price is expensive, and it is usually only used for the welding of key components.

Among the four materials, the temperature rise of aluminum alloy supercharging node is the highest. Too high node temperature will reduce the resonant frequency of the supercharger, and then affect the welding quality. This ultrasonic supercharger is not suitable for mass and long-term processing. The temperature rise of titanium alloy horn joint is the smallest because its internal damping is small. Compared with other materials, it works more stably at resonant frequency. In alloy steel supercharger, low carbon steel can withstand higher working temperature and higher welding strength than stainless steel. Among the weld strength obtained by ultrasonic welding of ABS plastic samples, the weld strength obtained by pressurized welding of titanium alloy is the highest, because titanium alloy material has small internal damping and energy loss. Low carbon steel, aluminum alloy and stainless steel enhance the weld strength in turn.

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