Dukane iq series User Manual page 127

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Problem
Internal components are welding together.
Probable Cause
The internal components are made
of the same material.
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Problem
Diaphragm Damage
Probable Cause
Excessive horn amplitude.
Excessive exposure to ultrasound.
Improper gate location/design/thin-
wall sections.
The type of horn and/or its placement.
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Problem
Overwelding
Probable Cause
Too much energy is being transmitted
to the part.
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Dukane Manual Part No. 403-586-02
Welding
Solution
Make the internal components out of
different materials.
Carefully lubricate the internal parts.
Use less horn amplitude by changing to a
lower gain booster.
Solution
Reduce the horn amplitude.
Dampen the welding area to absorb the
amplitude.
Reduce the weld time and increase the horn
amplitude and/or air pressure.
Check gate placement.
Change the shape of the gate.
Add stiffening ribs to the part.
Increase the thickness of the material on
the underside of the gate area.
If using a 20 kHz system, consider using
a 30 kHz or 40 kHz system.
Check for the proper horn/part fit.
Change the horn.
Solution
Reduce the air pressure.
Reduce the weld time/primary weld
characteristic.
Change to a lower gain booster to reduce the horn
amplitude.
Reduce downstroke speed.
Section 9 - Troubleshooting
Continued
Page 119