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One of the most popular methods for joining polymers is ultrasonic welding, which is favoured for its efficiency, adaptability, and affordability.
As part designs get more complicated and specifications become stricter, there has recently been a desire for more controlled and reliable ultrasonic welding methods.
Strong, dimensionally uniform pieces with acceptable aesthetics are also required.
The method utilised to satisfy these growing expectations needs to be dependable and predictable over time.
Amplitude, force, and time are the three basic process factors in the ultrasonic welding process that directly affect the weld quality.
Via a variety of evaluation techniques, it has been demonstrated that the servo welder consistently produces more repeatable outcomes.
Moreover, “high repeatability of collapse distance from part to component” is another benefit of the servo-driven ultrasonic welder.
The rate at which air can leave the cylinder in a pneumatic system is constrained, preventing abrupt changes in velocity and limiting distance control.
In ultrasonic metal welding, the oxide film on the metal surface is removed by applying ultrasonic vibration to the work, impurities in the surface layer are distributed, and a solid phase bonding condition is created by using the attraction force between the metal atoms.
Servo welders give the operator the opportunity to regulate hold distance and velocity during the latter stage of the welding cycle, in contrast to pneumatically driven welding machines.
For the joint quality, the hold phase of the ultrasonic welding cycle is crucial. In this stage, the weld is created, and the final microstructure that will determine the strength of the connection is established.
It’s possible to categorise the ultrasonic welding cycle into four main parts.
The Global Servo Ultrasonic Welding market accounted for $XX Billion in 2023 and is anticipated to reach $XX Billion by 2030, registering a CAGR of XX% from 2024 to 2030.
The launch of servo-controlled ultrasonic welding technology developed with the company’s Melt-Match technology was announced by Dukane Corp.
In comparison to pneumatic ultrasonic equipment, the system is intended to provide superior repeatability, lower manufacturing costs, and improved validation and calibration.
The Melt-Match technology, which enables exact control of the collapse speed, enables these system advantages.
According to the manufacturer, improving the collapse speed during the weld and hold phases produced better pull test results.
Dukane did an experiment with a client who was a medical equipment maker to back up its claims.
Several industries employ thermoplastic ultrasonic welding to quickly join two pieces together without the use of extra consumables like fasteners, adhesives, or solvents.
Unique levels of control are now introduced throughout the welding cycle thanks to the development of servo-driven ultrasonic welders.
