Ultrasonic welding is one of the staple industrial process and techniques currently used by different industries in the world. The products that can be produced and manufactured through this industrial process are quite extensive. From metal roofing Sydney to car roofing, there so many applications of this process. Since this process is economical and is apt for mass production of certain products, manufacturing companies greatly depend on it. Because of this process’ effectiveness and efficiency, many industries continue to rely on it when manufacturing certain materials and products.
In the book “Handbook of Plastics Joining: A Practical Guide” authored by Michael J. Troughton, the process of ultrasonic welding was thoroughly discussed. According to the book, this process is one of the most widely used welding methods for joining thermoplastics, uses ultrasonic energy at high frequencies (20-40 kHz) to produce low amplitude (1-25 µm) mechanical vibrations. The vibrations generate heat at the joint interface of the parts being welded, resulting in melting of the thermoplastic materials and weld formation after cooling.
Ultrasonic welding is the fastest known welding technique, with weld times typically between 0.1 and 1.0 seconds.” Throughton added that aside from welding, this technique’s “ultrasonic energy is commonly used for processes such as inserting metal parts into plastic or reforming thermoplastic parts to mechanically fasten components made from dissimilar materials. When a thermoplastic material is subjected to ultrasonic vibrations, sinusoidal standing waves are generated in the material.”
With the seemingly simple yet very effective use of this technique, many industries are dependent on it. Today, many of the things you see around you were manufactured with the help of such industrial processing technique. However, this does not mean that this technique and process only provide heap of advantages. Just like any other industrial technique, this type of welding also has a fair share of disadvantages.
There are countless advantages and benefits associated with this type of industrial welding, but it also has its down sides. In relation to this, it is essential and critical to tackle the pros and cons of this process. Below are some of the advantages and disadvantages of using this process for industrial purposes.
- When using for mechanical fastening, welding through the use of ultrasonic energy is efficient on any materials. It is also provide low-cost service, which is beneficial when creating prototypes and products of small batches. However, for multiple small components, this technique may cost more as it requires more intensive labor. Also, it may loosen when the product is used.
- This technique is also effective in adhesive bonding. Adhesives may be used for materials that are not compatible for welding. The technique also promises low cost in producing small batches of products and materials. Although it is effective in adhesive bonding, it may take longer time to join the parts and may need to be clamped until they bond. There is also some safety risks involved as the process may emit harmful gases.
- For low frequency vibration molding, welding via ultrasonic energy is also effective. The technique has the capacity for larger components other than ultrasonic. However, it would require relatively complex equipment, and may only be suitable for axi-symmetric welds.
- This type of welding is also used for hotplate welding. It has capacity of larger components other than ultrasonic. It is also good for thin, conductive materials like laminated metal-plastic foils.
Despite the number of disadvantages of this type of industrial welding, including metal roofing Sydney, automotive roofing welding, it is considered one of the most effective, practical, cost-efficient, and fastest techniques for welding dissimilar materials. Because of this, many industrial companies provide such industrial technique to consumer products companies that require faster turnaround and more reliable welding technique.