Evaluation the Effect of Ultrasonic Welding Parameters on the Welding Quality of Thermoplastics, an Experimental Study

Ultrasonic welding is a well-known and common solid-state welding method using high-frequency and low-amplitude mechanical vibration to join thermoplastics and thermoplastic composites since it is economical, fast, and easy to automate. In recent years, thermoplastic composites have found widespread usage in most modern industries because they are cheap and have unique mechanical and thermal properties. This welding method has several main parameters that can affect the final mechanical properties of the joint. This paper investigates the effect of ultrasonic welding's main parameters, including workpiece material and thickness, welding force, welding power, and tip’s material on welding strength of Polyvinyl Chloride (PVC), High-Density Polyethylene (HDPE), and High Impact Polystyrene (HIPS), which are three common thermoplastic polymers. The results show that welding force and welding energy significantly influence the final tensile strength of the joints. In addition, the material of the ultrasonic welding tips and material and thickness of the workpieces play a vital role in the final properties of the joint.

Keywords:

“ultrasonic welding” , “composites” , “thermoplastics” , “polymers”