How Ultrasonic Welding WorksThe technique uses ultrasonic, high-frequency acoustic waves instead of heat or electricity. As two components are secured under pressure, the ultrasonic welder emits high frequency sound waves that travel through the materials. When the waves locate the contact point, they cause the materials to vibrate, which generates friction, creating the heat that makes the components melt. After the waves are finished, the parts form a resilient bond as they cool and harden. This process does not require soldering or the use of metal fasteners, adhesives or other binding materials, such as thread.
Common ApplicationsThis equipment is used to fuse contact points on cell phones and other consumer electronics that are generally inaccessible with other welding methods. These techniques can be adapted to a wide range of commercial and industrial applications. In the food industry, the ultrasonic welding process is used to create a hermetic seal. It can fasten blister packs and facilitate the manufacturing of a variety of products, including toys, disposable lighters, pipettes and intravenous catheters.
Ultrasonic welding is commonly used in the plastics, aerospace and automotive industries to join similar materials. It is particularly useful in the production of medical products. Since the process does not introduce exhaust or other contaminants and the welds do not degrade, the manufacturing equipment can be used in a clean-room environment.