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Horn
The horn is selected or designed for a specific application. Each horn is tuned typically as
a half-wave section that applies the necessary force and vibration uniformly to the parts to
be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The
horn is mounted to the booster as part of the ultrasonic stack.
Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or
catenoidal. The shape of the horn determines the amplitude at the face of the horn.
Depending on the application, horns can be made from titanium alloys, aluminum, or
steel. Titanium alloys are the best materials for horn fabrication due to their high level of
strength and low loss. Aluminum horns are usually chrome- or nickel-plated or hard-
coated to reduce wear. Steel horns are for low amplitude requiring hardness, such as
ultrasonic insertion applications.
Dynamic Trigger Mechanism
The Dynamic Trigger Mechanism ensures that pressure is applied to the part prior to the
application of ultrasonic energy. This adjustable, pressure-activated device is located
between the air cylinder and the converter.
To maintain horn-to-part contact and force as the joint collapses, springs provide dynamic
follow-through. As the plastic melts, the springs extend to ensure smooth transmission of
ultrasonic energy into the part.
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