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C.2.3 The Booster
Success in ultrasonic welding, staking or inserting often depends on the
right amplitude of movement at the horn face. Amplitude is a function of
horn shape, which is largely determined by the size and form of the parts
to be assembled. The booster may be used to modify the amplitude of
vibrations applied to the parts through the horn.
The booster is a resonant half-wave section of aluminum or titanium. It is
mounted between the converter and the horn and provides a clamping
point for more rigid stack mounting.
Boosters are designed to resonate at the same frequency as the converter
with which they are used. Boosters are usually mounted at a nodal
(minimum vibration) point of axial motion, minimizing the loss of energy
and preventing the transmission of sound into the support column.
C.2.4 The Horn
The horn is usually selected or designed for a specific application. Each
horn is a half-wave section which applies the necessary pressure to the
parts to be assembled and transfers ultrasonic vibrations from the
converter to the workpiece.
Depending on their profile, horns are referred to as stepped, conical,
exponential, or catenoidal, with the shape of the horn altering the gain
factor. Depending on the application, horns may be made from titanium
alloys, aluminum or steel. Titanium alloys are the best materials for horn
fabrication. Aluminum horns are usually chrome- or nickel-plated or
hard-coated.
Theory
C-2
900IW+
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