Ultrasonic metal welding machine is a type of equipment that uses ultrasonic vibrations to join two metal pieces together. It is commonly used in the manufacturing industry for applications such as aerospace, automotive, electronics, and medical devices.
The ultrasonic welding process involves applying high-frequency vibrations, typically between 20 kHz and 70 kHz, to the metal pieces that need to be joined. The vibrations create friction between the surfaces of the metal, causing them to heat up and soften. The softened metal then fuses together to create a strong, permanent bond.
Ultrasonic metal welding machines typically consist of a power supply, a transducer, a booster, and a horn. The power supply generates the high-frequency vibrations, which are then amplified by the transducer and booster and focused onto the horn. The horn is then brought into contact with the metal pieces that need to be joined, and the vibrations are applied to create the weld.
One advantage of ultrasonic metal welding is that it can join dissimilar metals, such as copper and aluminium, which can be challenging to weld using traditional methods. Additionally, the process is fast, efficient, and produces welds that are strong and reliable.
✔ ULTRA UMWM 15 - 2600
✔ ULTRA UMWM 20 - 2000
✔ ULTRA UMWM 20 - 2500
✔ ULTRA UMWM 20 - 3000
| Frequency (kHz) | 20 | |||
|---|---|---|---|---|
| Power (Watt) | 3000 | |||
| Horn | Design as per the customized application | |||
| Actual Weight | Approx. 96 kg | |||
| Actual Size (L x W x H) | Approx. (605 X 556 X 1316) mm | |||
| Packaging Type and Size | Wooden Box and Approx. Size (752 X 703 X 1463) mm | |||
| Operational Requirement | ||||
| Input Power Supply | AC 230V 50/60Hz, 16Amp | |||
| CVT / Stabilizers | If the voltage is unstable then use CVT/Stabilizer to avoid damage | |||
| Working Pressure | 2 to 10 bars (Air Compressor required 1Hp 50Ltr) | |||
❑ Direct joining of materials with dissimilar properties.
❑ Very short welding times (fractions of seconds)
❑ Low heat generation in the welding joint
❑ Strength in the joints close to the base materials
❑ No additional joining material required
❑ Low thermal and electrical transfer resistance
❑ Can easily be integrated into automatic production lines with options for welding parameter recording / quality control
❑ Cold welding technique with temperatures of approx. 30-40 % below melting temperature
❑ Breaking up of oxide skin and flattening of surfaces until atomic bonding forces come into effect
❑ Diffusion of different materials with each other within fractions of seconds
❑ Optimum strength since no micro structural changes occur in the boundary layer
❑ Helium tight metallic joints
❑ Speed
With the compatible parts, the high-frequency ultrasonic vibration can weld parts quickly. As a
result, ultrasonic welding technology guarantees a fast production process, high throughput, and short turnaround times.
❑ High Level of Safety
Due to the indirect application of heat, there is a reduction in operational hazards. Aside from that, heat generated by the process is localized and quickly dissipated. Hence, there is no damage to
the welded joints and the surroundings of the materials to be welded.
Using ultrasonic welding equipment is extremely safe compared to other welding techniques. The ultrasonic energy is highly targeted, reducing the risk of dangers due to excess electrical energy. Additionally, the heat produced is minimal, ocalized and quickly dissipated, minimizing the thermal impact on the material and reducing the chances of excess heat damaging any surrounding equipment.
❑ Reliability
Machines used for the welding process are reliable as they experience minimal breakdowns and faults. Furthermore, with automation, there is a reduction in operational and human error, operation cost, and improvement in welded joint quality.
Suitable for Dissimilar materials It is a suitable process for welding different materials - an important attribute needed in plastic welding. In contrast, other plastic welding processes are unsuitable for dissimilar plastic materials because there is no molecular bond formation.
❑ Minimal Material Costs
The process doesn't require consumables, unlike other joining processes (see the difference between welding and riveting), which use connective bolts, solders, and other adhesive materials. Due to that, it is more cost-effective.ually no time is needed for drying or curing” By “Due to that, it is more cost-effective. All no time is needed for drying or curing.
❑ Joint Quality
The welded joint does not have defects such as plastic flashes, deformation, or fault. As a result, the welded joint has a high quality, clean, and invisible seam.
❑ It saves time.
It is much faster than traditional welding methods, as virtually no time is needed for drying or curing.
It saves production costs.
❑ Flexibility
Ultrasonic welding can be applied to a variety of materials and parts. Thermoplastics and several metals can be welded using this technique, and it is especially useful in welding dissimilar materials. Additionally, ultrasonic welding can weld thin to thick material combinations.
❑ Reduced material costs:
The ultrasonic welding process is very cost-effective in terms of material usage. The process doesn't use connective bolts, solder or adhesive material, so it helps to reduce material costs for
the project. Also, because ultrasonic welding is highly precise and produces high-quality joints, part scrapping is kept to a minimum. The ability to minimize human intervention during and after the welding process also keeps labour costs to a minimum.
❑ Medical Industry
❑ Automobile Industry
❑ Aerospace Industry
❑ Electronic industry
❑ Battery production
❑ Welding of the large heat sinks
❑ Welding of heat exchange fins and honeycomb cores for various household appliances
❑ Welding of automotive products.
❑ Welding electromagnetic switches, useless switches
❑ Welding of dissimilar metal sheets.
❑ Welding of the end of metal tube to prevent water and air in filters
❑ Medical industry uses it for welding face masks, blood and gas filters, and arterial and anaesthesia filters
❑ Automobile industry uses it to join plastics and make components such as door panels, instrument panels, and steering wheels
❑ Manufacturing parts for the aerospace industry
❑ Used in electronic industry in joining wired connections
❑ Ultrasonic metal welding can be used with copper, aluminium, nickel, silver, and gold.
Electronic industry
PP Corrugated Box
Battery production
Automobile Industry
