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Hostaform
Acetal
copolymer (POM)
Hostacom
Reinforced polypropylene (PP)
Celanex
Polybutylene terephthalate (PBT)
Hostalen GUR
Ultrahigh molecular
weight polyethylene (PE-UHMW)
Fortron
Polyphenylene sulphide (PPS)
Vectra
Liquid crystal polymers (LCP)
registered
trademark
Contents
1.
Introduction
2.
Design
6.
and
operation of an
ultrasonic welding unit
Notes
Ultrasonic
welding
Hostaform
6.2
ultrasonic welds
3.2.1
3.2.1.1
3.2.1.2
3.2.1.3
3.2.2
3.2.3
3.2.3.1
3.2.3.2
4.
7.
affecting
welding properties
Effect of the moulding compound
Effect of melt viscosity
Effect of pigments
Effect of reinforcing materials
Ultrasonic
Fortron
7.2
Vectra
8.
Other ultrasonic
8.1
8.2
assembly
17
17
8.3
Riveting
Flanging
Staking
8.4
19
19
19
welding conditions
Requirements for the welding equipment
Effect of welding conditions
9.2
part
Time control mechanism for
9.3
22
9.4
23
9.5
23
the joint
10
9.
Examples of applications
9.1
Sewing machine control
9.6
Different
Joints
joint designs
11
knob-shaped
11
for
design
larger components
Joint designs for pinch welds
Double pinch weld with symmetrical
12
joint surfaces
pinch
surfaces
joint
13
5.1.3.2 Double
cycle
22
22
a toaster
22
time
24
11
energy directors
5.1.3.1
methods
5.1.2.1 Weld
5.1.3
17
energy directors
5.1.2
16
16
(PPS)
(LCP)
Designing
5.1.1
16
Factors
Procedure for
5.1
15
7.1
calculation
5.
14
14
(POM)
of Hoechst
engineering plastics
3.1
Requirements for optimum
3.2
ultrasonic
6.1
6.3
3.
on
weld with
12
asymmetrical
13
10. Literature
24
1.
Introduction
2.
an
or
extrusion
ultrasonic
blow moulded
thermoplastic components by
welding is a cost-effective technique which has proved
particularly suitable for long runs because of the very
short welding cycles.
welding unit
The
are
transmitted
Ultrasonic
ultrasonic
an
ultrasonic
ultrasonic
The
Detail "A"
The Hoechst
and Hostacom
weld and
welding
on
method
the
most
depend
not
F*l
suitable type of
only
on
the
mate
design
requirements it has to
ly to the given test specimen geometry and machine con
ditions. Even slight deviations can lead to different
results. It is therefore almost impossible to draw general
conclusions. For critical applications we recommend
contacting us first.
1 Ultrasonic converter
2
Top
resonance
unit
3 Ultrasonic horn
part
5 Bottom part
6 Jig for the bottom part
7 Energy director
'")
Travel
high
stresses
alloys.
or
high strength
alu
The parts
welding of
Hoechst engineering plastics
3.1
variable.
Various
equipment
quality
of
Ultrasonic
3.
the weld:
Correct
vibration
contact
amplitude,
of the weld.
pressure,
welding time,
welding distance
hold time (cooling time)
the
The vibration
limits
to
amplitude
resonance
sizes
unit of
an
surfaces should
joint
than 6
adaptors of different
see 2 in fig. 1.
The
can
mm
at
close range
1 Horn
2
3
Top part
Energy director
4 Bottom part
the
sympathetic vibration of
welding operation I),
corners, edges and transitions should be adequately
radiused (to prevent notch effect),
welds should as far as possible be arranged in a single
plane (contact surface) at right angles to the horn axis
(fig. 3)
diaphragm effect, fig. 4,
areas not
i.e.
involved in the
Fig.
Design
3:
of the
parting line
Fig.
5:
Design of contact
Fig.
6:
Clearance S
area
"a"
~A//////, y/////^
y,
/,
S\
good
\
^
$
$
\
\
\
\
\
^
$
$
s
\
\
\
\k
bad
1y 2 i y1
\
//////. //////,
|
\
-',
S
~\
\
\
\
mm*.
_____-
\
\
\
\
\
\
\
the
joint
parts and
good
=
0.05
to
0.1
bad
\
\
\
Parting line
\\\\\v\ k\\\\\V
Fig.
required for
alignment overlap Z
minimum
4: Wall thickness
design
two parts should be perfectly aligned so that they
remain in position when vibratory energy is applied.
the
The
S^^$
on
bad
contact area
because with
too
not
be less than 1
mm
small
an area
adequately
3.2
Factors
the ultrasonic
To find the
not
by interposing
and part.
avoided
(risk of damage:
diaphragm effect I)
large
should
(fig. 6).
projecting pins, ribs, tabs etc. are prone to sympathetic
vibration during ultrasonic welding and may therefore
melt and be damaged. This can be countered by using
larger radii, additional supports or elastic pads,
the
the horn
alignment overlap
be
too
great
of
important
number
solution
to
welding problems,
factors have
to
right
These
concern
material
3.2.1
3.2.1.1
As
Hoechst
This
ty)
as a
Fig.
7:
curve as a
function of
8000
(torsion pendulum
test
6000
4000
T
2000
T I
1
0
a
1:1
Amplitude
Hostaform
b Hostaform
c Hostaform
d Hostaform
a
1:1.5
C
C
C
C
1:2
1:2.5
transformation
27021
2521, T 1020
J A range of scatter
-80
-40
40
80
120
160
Temperature
to
grade
can,
vibration
Provided these
properties
and
requirements
given
produced from partially
crystalline thermoplastics can be ultrasonically welded,
particularly by the close-range method (see section 2).
are
or
contact
pressure,
welding time,
welding distance.
for
3.2.1.2
additions.
Suitability
can
be influenced
Effect ofpigments
specified
test
test
on
pieces.
welding properties
has
apply
conditions.
Fig.
pigments in Hostaform
joints
strength
Fig.
9: Effect of different
C 9021
on
the
10:
in modified
Hostaform
of welded
UUU
suuu
6000
8 4000
1 I T I I
T I
6000
0
^
T
4000
rt
"
'
2000
JL
?nnn
(5
1
1:1
1:1.5
Amplitude
h c d
1:2.5
1:2
t
ansformation
n
rt
es
(M
fi
<N
IS*,
in
vD
rO
fl
r*%
,C
fx
f
O
fl
fc- o
>>
>-,
>>
<u
CJ
tu
(U
_>
>
fe
range of
ex
rx
rx
J4
-o
X
_id
tu
a>
M>
Hostaform C 902 1
b Hostaform C 9021 K
c Hostaform C 9021 TF
a
tTi
rt
rt
IS
J3
_Q
11:
Fig.
scatter
in Hostacom and
Hostalen PP
The
large
range of
scatter
can
be reduced
3UUU
by adjusting
N
4000
3000
T
i
i
2000
D,
rt
^
3.2.1.3
Effect of reinforcing
0
a
Amplitude
1:2
1:L5
Modification of Hoechst
1:2.5
transformation
Hostalen PP.
linked)
Hostaflon (PTFE)
content
in Hostaform C 9021 TF
strength
of welded
Thermoplastics impact-modified
are more
difficult
grades. Suitability
content.
The
to
plate welding
contact
1:1
glass
additions
The
T T
1000
and
is
slightly
welding time).
As far
apply
as
as
same
points
3.2.2
The parts
and as far
to
as
To achieve
be welded
must
be
dimensionally
possible
tions
(see
given in the
Literature).
are
10.
accurate
stresses.
The
welding equipment
has
to meet a
number of
require
ments:
3.2.3.1
condi
processing
product brochures
relevant Hoechst
high repeatability
sensitive
results,
control,
sufficiently high
contact
of
output reserve,
welding time and hold time
pressure,
must
be
To
ensure
are
correct
location and
the
cross-section
following points
the
right
avoid
3.2.3.2
of identical
articles,
multi-cavity production
take into account post-shrinkage to ensure dimen
sionally accurate mouldings,
do not weld parts immediately after injection mould
ing; a delay of at least 24 hours is recommended.
3.2 .3
infinitely variable,
time- and stroke-dependent control should be
possible,
the possibility of choosing between time-, stroke- and
energy-control operating modes extends the area of
application.
context
tance
ment to
operate
welding
tool
welding
squeezing more melt
than necessary out of the welding zone.
The risk of thermal degradation of the moulding
must be absolutely avoided, if necessary by reducing
welding time.
Prolonged welding times, excessive contact pressure
or unfavourable positioning of the joint can lead to
damaged mouldings. This may not be apparent imme
diately after welding but can cause failure at a later
stage during service (creep effect).
ensure
Correct selection of
zone
for
welding but
to
avoid
Procedure for
4.
optimizing
welding conditions
of jig
to
preliminary
be carried
ing
out
joint
or
this stage
Optimization
surfaces
are
to
to
opti
to
the mould
and
make it easier
to
'///////////////////////
in the
optimization
of
welding
conditions:
Stage
Stage
1:
4: Hold time
The vibration
be matched
the
parti
amplitude
welding problem. This is most easily
achieved by carrying out preliminary trials with different
amplitude transformers (see. fig. 1). For welding Hoechst
engineering plastics, amplitudes of 10 to 30 //m are nor
mally used.
to
to
Stage
2:
the
Selecting
contact
pressure
The
3:
Welding
time
(ultrasonic
exposure
time)
Note:
10
to
and 2
part,
see
s.
are
applications, the
worth considering:
start
(cooling time)
is
It should be established in
critical
the horn
vibrating
before it is
applied
to
the
top part,
The
General rule:
Stage
jig
time-consuming. It
harden the injection moulds
costly
not to
be
often has
is therefore advisable
at
trials.
must
1 horn
2 top part
3 bottom part
sum
of the
welding
Figs. 15 to 19 show some successful joint designs with roofshaped energy directors. Their dimensions may be altered
within certain limits. Special shapes are also possible.
5.
In ultrasonic
welding,
the
joints
designs
depending on
be provided with
shape
energy director
Fig.
14:
Roof-shaped
Fig.
15:
must
and size of
possible
The
in the
same
basic
following
situation.
designs
are
possible:
5.1
5.1.1
energy directors
weld is concealed
Energy directors of this type (fig. 13) are used for joining
components with relatively flat joint surfaces. They are
not
suitable for
Fig.
sealing
to
can
escape
welds.
foO
=60
on
The
90
0.5
to
1.0
to
90
mm
^SSSSS
0.05
to
0.1
Fig.
nearly
director has
an
energy directors
(fig. 14)
can
be
60jo_90
mm) according
to
mm (in special
requirements.
cases
up
to
^m
Ai
~r
g
U1
0.05^
0.1
to
11
5.1.3
Fig.
17:
should
Top
preferably only
be used for
relatively
small
parts.
1
M
^{^^
Pinch welds
Some successful
in
0.05
to
figs.
21
to
0.1
Fig.
20:
Principle
of
joint design
0.05
5.1.2.1 Weld
Fig.
to
for
pinch welds
0.1
L^;^^
(reinforced PP).
Fig.
Fig.
crystalline plastics.
12
are
23.
21:
Joint designs
for
shown
Fig.
22:
Joint designs for double pinch welds (a) with and (b) without
Because of the
high
dimensional accuracy
required,
should
preferably
an
be used
sional tolerances.
0.3
to
0.4
asymmetrical joint
surfaces
and
(fig. 24)
not
is used for
joints
be sealed. Much
Fig.
to
same
criteria
apply
in
elements.
Fig.
24:
preferred
weld form
13
Notes
6.
ultrasonic
welding
of moulded parts made from
Hoechst engineering plastics
on
Fig.
minimum
after
0.1
gap
welding
mm
Hostaform (POM)
6.1
Hostaform
range
too.
The attainable
practical requirements.
most
Good
Fig.
welding in
butt weld
40,Mm.
The minimum
0.3
mm.
As
should be 1/5
The
melt
can
0.1
to
moulding by
to
the
occurs
The Hostaform
the
14
25 and 26 show
differ in molecular
weight and
properties on welding
specimens used were can-
behaviour
shaped
with
an
thickness of 3
the
tested. The
was
test
outside diameter of 30
mm.
joint designed
A lid
as a
was
double
same
welded
mm
onto
and
the
wall
can
can
with
and lid
examples
separation can be countered by suitable design of
joint contours, i. e. free sinking-in must be ensured.
two
grades
were
melt
mm
separating
very
rarely and usually only at isolated points it nevertheless
reduces joint strength and impairs sealing welds. Melt
separation such as this tends to occur where free sinking
of one part into the other is restricted at some point. It
is therefore important at the planning stage to prevent
these problems through suitable design of the joint con
tours. At the same time, the sink-in depth should be suit
ably limited through the provision of horn travel control.
Figs.
gap
welding
alternating
the horn
height
minimum
after
basic
8uOw
Hostacom
6.2
(reinforced PP)
6000
^
r-i
_.
__
grades
can
only
be welded
at
4000
2000
29
0
C 52021
C 27021
C 13021
C9021
C2521
(48)
(28)
(13)
Basic grades
(9.5)
(2.5)
^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^m
(The figures
Frequency
20 kHz
Amplitude
Welding pressure
Welding time
30 1* m
1.8 bar
Weld design
Generator output
(left bar)
(right bar)
double pinch weld
0.6
1.0
sec
sec
4000
700 W
3000
^
cs
_o
uc
.5
2000
rt
OJ
<a
1000
8000
N
PPN 1060
G2N01
G3N01
non-reinf.
M2N01
M4N01
reinforced
6000
"i
J
&c
4000
'Si
E
CQ
2000
If]
IE
C9021
C9021
GV 1/30
GV 3/30
(4.5)
(9)
S 27073
(22)
Reinforced grades
Frequency
Amplitude
20 kHz
Welding pressure
Welding time
Weld design
1.8 bar
Generator output
30,
1.0
sec
double
700 W
pinch
weld
S 27076
S 9063
S 9064
(17)
(9)
(8)
(The figures
Frequency
20 kHz
Amplitude
30,
Welding pressure
Welding time
1.8
Weld design
Generator output
bar
(left bar)
(right bar)
double pinch weld
0.6
1 .0
sec
sec
700 W
15
Celanex (PB T)
6.3
The
breaking
assembly of
performance polymers
specimens made
long-range
horn and joint sur
from Celanex
are
shown in
fig.
30. Even
welds
The Hoechst
test
8000
N
6000
1
g"
Ultrasonic
7.
problem
4000
or
effectively
amplitudes.
can
smaller
remedied
be
to
by higher frequencies
so
2000
between the
cooperation
producer
user,
equip
is essential.
0
2500
2300
2360
GV 1/30
GV 1/30 H.
non-reinf.
reinforced
Frequency
20kHz
Amplitude
Welding pressure
Welding time
30 fim
1.8 bar
0.6 sec
1 .0 sec
Weld
design
Generator output
(left bar)
(right bar}
double pinch weld
700 W
Here
7.1
Fortron
(PPS)
near-
Additions of
Tapered pinch
1
16
mm can
welding distance
made gas-tight.
welds with
if necessary be
of
over
Vectra
7.2
The
by
welding
(LCP)
Other ultrasonic
8.
behaviour of Vectra is
uniquely influenced
properties and molecular
the joint parts. Particularly good results are
assembly
methods
orientation in
best be
on
met
surfaces
runs
(angle
of inclination 10
to
15).
Ultrasonics
Ultrasonically
welded Vectra
moldings
are
gas-tight.
cooling
die.
8.1
Riveting
so can
also
assume
way is allowed
to
assumes
produced
Single and multiple riveting
operation.
The
riveting
in the desired
die and is
time
can
shape
riveting
be carried
out
on
in
one
the material
following points
ing:
the
projecting
proposed
rivet
head,
slowly,
contact pressure should be lower and amplitude
generally higher than in ultrasonic welding,
the horn should be held in position until the rivet
head freezes,
the end of the horn may be subject to wear (especially
in the case of glass fibre reinforced plastics).
the material
the
being riveted,
required strength,
17
Fig.
31
Recommended rivet
pin
Head
Diagram showing
design, workpiece
horn
design
designs
Diagram showing
horn design, workpiece
Head
Rivet
design
diameter
pin
L^,
"~"f2Z
^^
-^> \
rL-
fc
XXXX./.^.
^k
Xkx
N. X \
""i Yr~~
\gm
^|
'//////////A
Y//////////,
-i
^75 d
^
C
>B3
L^*J
IXXXXXXT XIX
^~%~-/
i
-*H
'//////////A
3'
'Y
<k/
"*ttfe^
r>xX
kg
t^>^w>^_a
V////*/////.
^->
<^l
/v4?^.
tx \\\ ^^/ti..^ \x\^
Y////// ////
IvXXXXY
R\l
d>2
d>0.5
^>^x>
XN
_Jl/R
;fy A\\\
'
sssEfes
/////%////,
C^
^
18
<T<A
V/;/7/\/////s 1
T3
/R
2dJ-,-
.of
r-^-T-x-^l
ri "> 1
\o
*v xxxxrxixxxxx
-ni
\\N-Y
V/////Y/ //X/
TJ
'////</////,
_4L5di
-^i
XR
*-/
FK|
\\V
t
t
vO
s
i
CN
'////Y////'
\XX XXN'
y y
/ f
-1
05
?\
^k*-/
XXXN
/////X////
///7)Cr///.
G
fa /R
x^^i^
Y///////,
1
designs.
preferably employed for
designs
about
3
thin rivet pins up to
mm diameter. Head designs
C and D have proved particularly successful. In these
designs, the contact surface between the horn and rivet
pin is through the central tip which must be applied cen
trally and initially represents a very small area. The ultra
sonic energy is introduced through this area. Head design
D is preferred because of the good strength values it gives.
In design E, the horn face is knurled. This design has
proved successful for single, and particularly, for multiple
riveting. It enables positional inaccuracies between the
horn and rivet pin and dimensional tolerances in the
spacing between a number of rivets to be accommodated.
If large rivet pin diameters are required, it is advisable
to use hollow pins, fig. 31 design G or several thin pins
to avoid sink marks when injection moulding the parts.
Fig.
31 shows
some
In
frequently
A and B
Rivet head
riveting glass
thermoplastics, a higher
required than for the non-reinforced
fibre reinforced
ultrasonic output is
material.
of
In
glass
wear
Figs. 32 and
flanging.
33 show
examples
metal
plate
in
plastic
with
Flanging
8.2
are
are
reinforced
resistant
check whether
hot
In
riveting mouldings
Celanex, it is important
not
only to optimize
rivet head
(fig. 31)
to
Before
After flanging
flanging
select
when
riveting
the
1 Plastic housing
2 Ultrasonic horn
3 Metal
plate to be
fixed
recommended:
Fig.
pressure
commensurate
welding
time
with
to
be
flanging, fixing
plastic pipe
stub into
amplitude,
speed,
commensurate
material
33: Outside
container base
convert
Before
flanging
After
flanging
1 Metal base
2
Ultrasonic horn
Pipe stub to be attached
19
Staking
83
34:
In the
case
least 2
to
recessing
mm
to
accommodate the
at
least 2
mm.
advantage
to start
the horn
before ap
introduce the ultrasonic energy
displaced mol
plastic.
It is
re-forming
of blind
tion should
inserted.
only
During
rate
very
vibrating
slight
contact
pressure.
applica
ted.
Fig.
integrally moulded
plastic part
R>0.2
Insertion
8.4
of metal parts
achieved.
Fig.
35 shows
With this
some
examples.
jointing technique,
the
following points
should
be observed.
the
fig.
The
junction
body
of the
plastic
part,
35.
receiving hole
must
be
slightly
20
boss
to
Table 1: Recommended
Metric
thread
receiving
Dian icter
Length of
bushing
1
hole diameter
Dl
D2
4.0
4.7
4.3
M4
7.5
5.2
6.15
5.65
M5
9.0
6.4
7.35
6.85
M6
10.0
7.7
8.75
8.25
M8
12.0
9.7
Metric
Length of
bushing
Threaded insert 1
D2
1 1 II
11.3
Diari icter
D2
Dl-l
10.8
Receiving
hole diameter
Dl
mm)
(guide values)
5.5
in
Receiving
M3
thread
(dimensions
Threaded insert 2
(guide values)
M3
5.8
3.9
4.7
4.0
M4
8.2
5.5
6.3
5.6
M5
9.5
6.3
7.1
6.4
-D2
l
\
1T
1
\.
M6
12.7
7.9
8.7
8.0
M8
12.7
9.5
10.2
9.6
1
i
-Dl-
21
Examples of applications
9.
9.1
cam
top part
bottom part
suitably
contoured horn.
for a
toaster
0.05
<:
\
*
housi
-H*)0\
,-^s
be
every time
exactly
housing and top
set
to
toasting
suit individual
time
taste.
to
The
9.3
-tf
0.05
to
0.1
top
45
tank
This
lighter comprises
22
0.05
These
to
0.1
assembly,
the bores
ultrasonic
welding.
are
by
regulator
4-
housing
0.05
to
0.1
0.4
These
23
9.6
time calculation
-ir\
fpYsltlJYP
A gas
closed
mem
pneumatically.
of the parts
to
cycle
placement of the tank
pneumatic jig closure
in the
Energieum-
Kunststoffen.
von
H. Potente:
Thesis, TH Aachen.
G.
H.
[s]
jig, including
1.5
Menges,
be
Determination of
O
place-
G.
Menges,
Potente, D. Pieschel:
Schweibarkeit
von
Kunststoffen
Vorhersage
der
bekannten Werk-
aus
1.0
0.5
vol. 25.
0.5
R. Martin:
application of horn
welding time
0.5
Plastverarbeiter 1978,
positioning
of the top
6/1972.
no.
Gasfeuerzeugtanks
no.
aus
8, pp.
Hostaform,
419
hold time
1.0
H. Vowinkel: Ultraschallschweien
removal of horn
0.5
Acetalcopolymerisat,
ejection
N. El Barbari:
424.
von
Formteilen
aus
0.5
is
von
Thermoplasten, Mglichkeiten
der
Einsatzoptimie-
rung.
9600.
Plastics, Hostaform"
B 244.
The
forced
PP)",
H 703.
Impet",
B 243.
(PPS)",
(LCP)",
mouldings
and semi-finished
ZVEI, Stresemannallee
D-60596 Frankfurt
a.
B 241.
assembly of thermoplastic
products",
19
M.
24
B 240.
Useful addresses:
Engineering plastics
Design Calculations Applications
Publications
Ultraschalltechnik,
Descostrae, D-76307 Karlsbad-Ittersbach
so
Herrmann
A.
Engineering plastics
properties
A. 1.2 Grades and properties
A. 1.4 Grades and properties
A. 1.5 Grades and properties
Vandar, Impet
A.2.1 Calculation principles
A. 1.1 Grades and
KLN
Ultraschall
Siegfriedstrae 124,
KVT
GmbH,
D-64646
Heppenheim
Bielefeld, Gesellschaft fr
A.2.2 Hostaform
calculation
Rinco
A.2.3 Hostacom
Ultrasonics,
CH-8590 Romanshorn/Schweiz
Telsonic
Ultraschallgerte GmbH,
Ravensburg
calculation
Hostaform
Hostacom
Hostalen GUR
Celanex,
examples
-
examples
Telsonic AG,
Industriestrae,
B.
CH-9552 Bronschhofen/Schweiz
worm
Hostaform
B.3.1
B.3.2
B.3.3
B.3.4
B.3.5
B.3.7
C. Production
C.2.1
C.2.2
C.3.1
C.3.3
C.3.4
C.3.5
of technical mouldings
Hot runner system
Indirectly heated,
thermally conductive torpedo
Hot runner system
Indirectly heated,
conductive
thermally
torpedo
Design principles and examples of moulds
for processing Hostaform
Machining Hostaform
Design of mouldings made from
engineering plastics
Guidelines for the design of mouldings
in engineering plastics
Outsert moulding with Hostaform
-
25
brochure, Hoechst
provide
exploit the properties
who
aims
to
designers
engineering polymers such as
Hostaform. In addition, our staff will be glad to advise
you on materials, design and processing.
of
edge
products
strued
and their
want to
to
uses.
on our
present
provide general
It should
not
state
of knowl
notes on our
therefore be
con
Copyright by
Issued in
26
Hoechst
August 199677th
Aktiengesellschaft
edition
Hostaform , Celcon
Celanex
Impet
Vandar
Riteflex
Vectra
Fortron
polyphenylene sulfide (PPS)
Celstran , Compel
GUR
Europe
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