What is energy director in ultrasonic welding?

The purpose of the energy director is to focus the ultrasonic energy at the apex, resulting in a rapid build up of heat. This causes the triangular section to melt and flow across the joint interface, forming a weld.

What industries use ultrasonic welding?

The applications of ultrasonic welding are extensive and are found in many industries including electrical and computer, automotive and aerospace, medical, and packaging. Whether two items can be ultrasonically welded is determined by their thickness.

How much does an ultrasonic welding machine cost?

$18,000 to $45,000
Ultrasonic welders cost anywhere from $18,000 to $45,000, depending on power capacity and bells and whistles, such as statistical process control packages. A basic 20-kilohertz, 2.5- to 3.5-kilowatt ultrasonic metal welding system can be acquired for around $30,000.

How is energy required for ultrasonic welding calculated?

The power required for ultrasonic welding: P=F*V, where F is clamping force, V is sonotrode vibration velocity. Since the ultrasonic vibration is a sinusoidal motion, V=Pi*f*D, where Pi is 3.1415926, f is frequency and D is peak to peak amplitude. F is determined by the clamping pressure (Pc) and welding area (A).

What is an energy director?

Energy Director monitors and directs the energy efficiency of a facility or establishment. They implement conservation methods, monitor energy consumption, assess the business for sustainability, and seek energy efficiency opportunities.

What are benefits of ultrasonic welding?

Ultrasonic welding offers some key advantages over other forms of welding:

  • 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.
  • It produces a high-quality bond and a clean, tight seal.

Who invented ultrasonic welding?

First invented in the 1940’s, ultrasonic welding for bonding thermoplastics went on to be patented in 1965 by Seymour Linsley and Robert Soloff. At the time, Robert Soloff was a lab manager at Branson Instruments.

What are the disadvantages of ultrasonic welding?


  • It cannot be used to produce large joints (greater than 250 x 300 mm).
  • It requires specially designed joints, so it can make tip contact during the welding process.
  • High tooling cost for the fixtures.
  • The ultrasonic welding process is restricted to the lap joints.

What is the maximum frequency used in ultrasonic welding?

Ultrasonic welding 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.

How do I become an energy specialist?

The qualifications to have a career as an energy specialist include a bachelor’s degree in urban and regional planning or in a science-related field. You need to possess strong analytical skills and have experience working with the support of assessments and compliance of large development projects.