Welding - Dukane iq series User Manual

iQ
Series Ultrasonic Press System LE User's Manual
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Problem
Flash (See also: Uneven Welding)
Probable Cause
Energy director is too large.
Shear interference is too great.
Weld time is too long.
Non-uniform joint dimensions.
Part fit or tolerances.
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Problem
Misalignment of the welded assembly
Probable Cause
Parts are not self-aligning.
Improper support in the fixture.
Wall flexure.
Joint design is not properly dimensioned.
Incorrect part tolerance/poor molding.
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Welding

Solution
Reduce the size of the energy director.
Reduce the weld time/primary weld characteristic.
Reduce the air pressure.
Use an interrupted energy director.
Reduce the amount of interference.
Reduce the weld time.
Re-dimension the joint.
Redesign the joint to be a shear joint or
a tongue-in-groove joint. Contact Dukane's Applications
Lab.
Check the processing conditions.
Loosen the part fit.
Loosen the part tolerances.
Solution
Design a means of alignment into the
tooling (fixturing).
Add a means of alignment (e.g., pins
and sockets) to the mating part halves.
Redesign the fixture for proper support.
Add ribs or gussets to the part.
With a resilient fixture, if large sections
of urethane are deflecting, add a rigid
backup.
Re-dimension the parts.
Tighten the part tolerance.
Check the processing conditions.
Continued
Dukane Manual Part No. 403-586-02