We launched new model ultrasonic spot welder with new look and new circuit design for celebrating the 70th anniversary of the People’s Republic of China. 
The Red color is our national flag color, and Red represents Good fortune and Happiness in China traditional culture.
With this new ultrasonic generator, we hope all of our clients around the world will make good business and generate good fortune in the coming years.....

We all know the basic rules of ultrasonic welding，high-frequency electric energy turned into high-frequency mechanical energy，this repeated vibration transfers to the thermal plastic or metal, generates friction and energy between the plastic to plastic, plastic to metal or metal to metal.
 
In the process of ultrasonic welding，the heat that generated by friction melts the two plastic surface into each other. In the process of ultrasonic riveting welding, the tip controls the flow direction of the melted plastic，forms, and then presses. in the process of ultrasonic nut imbedding，the welding tip injects the nut into the plastic.

 
Various ultrasonic system configurations could be chosen with different frequencies(15kHz-50kHz) and power (600W-4800W)，or different control methods ，such as pneumatic ultrasonic welder，servo ultrasonic welder or different applications like handheld welder，non-standard ultrasonic welder，metal welder etc.
 
Many factors affect the result of the ultrasonic welding: Mold (upper horn plus lower fixture)，frequency，material，welding line design，welding parameter and spare parts injection etc.





Welding system frequency
 
Typical welding frequency includes 15kHz，20kHz，30kHz，35kHz，and 40kHz. Appropriate welding frequencies could be chosen per the product sizes, inner electric components types, welding strength, welding result etc. Basically, the following principles could be referred:


For small and high-precision electronic products (containing PCB board and microelectronic component inside) housing welding, a 40kHz ultrasonic welder is often used. It has a smaller amplitude with smaller welding pressure to avoid damaging the inner electronic components.


1. For the small products with demanding requirements on the look, a 40kHz ultrasonic welder could be applied. Smaller amplitude and pressure help to weld a better looking.


2. For the plastic welding with medium or large size, 15kHz or 20kHz are usually applied.


3. For the relatively soft material such as PP, or the material with thin poor stiffness, low frequency and big amplitude, a 15kHz welder is normally applied.


4. For far-field welding-the welding horn is far away from the welding line, for instance, if this distance is bigger than 12mm, on this occasion a 15kHz ultrasonic welder could be used.


5. 20kHz welder is applicable to most small or medium-sized plastic welding, which is also the most widely used frequency in ultrasonic applications.



Material


1. For ultrasonic plastic welding，it only applies to thermoplastic welding for the thermoplastic could melt in a specific range of temperature. For the thermosetting plastics, it degrades while heating so it could not be welded by the ultrasonic.


2. The weldability of the thermoplastic depends on the stiffness, elasticity modulus, density, friction coefficient, heat conductivity coefficient, specific heat capacity，glass transition temperature(TG) or melting temperature(TM).


3. Generally,  a material with good stiffness has excellent far-field welding ability for it easily transmits the vibration energy, soft material with low elasticity modulus would be hard to weld for it decreases the ultrasonic vibration. On the contrary, for rivet or spot welding, the softer the material, the easier the welding.


4. Normally, plastics are divided into two types-amorphous and crystalline. The ultrasonic energy can transmit easily in the amorphous material so it is easy to weld. However, it is not very easy for the ultrasonic energy to transmit in the crystalline material so it takes a larger amplitude and energy for the ultrasonic welder to weld crystalline material, the welding line should also be designed carefully.


5. The weldability could further be affected by the factors such as water content, releasing agent, lubricant, plasticizer, filler reinforcers, pigments, flame retardants, and other additives, and actual resin grades. In addition, attention should also be paid to the degree of compatibility between different materials. There is a certain degree of compatibility between certain grades of some materials and not others.


It should be considered whether the welding is near-field or far-field welding. The distance between the welding tip contacting the plastic part and the welding line is less than 6mm is called near-field welding, if the distance is larger than 6mm, it is then called far-field welding. The longer the distance, the greater vibration attenuation，the harder the welding. 





Tooling & welding head
 
Generally, customers will choose the same brand tooling and welding head. In fact, as long as the frequency is the same as the equipment, other brands could also be chosen.
 
The welding horn material could be aluminum, titanium, or hard alloy steel. The tooling material could be aluminum, stainless steel, and resin mold. The material chosen normally depends on the material type, the material fiberglass content, connector structure and size, welding strength, and service life. For instance, to lengthen the service life of the welding horn, hard alloy steel could be a choice.




The ultrasonic welding horn could be designed and optimized by FEA (finite element analysis), which allows the engineer to evaluate the welding head vibration and pressure before actual manufacturing. An optimal welding horn design is one with uniform output amplitude and minimum stress. In the picture above, the left picture is the welding horn design before optimization, the right one is the horn design after optimization.
 
In the process of welding horn design and manufacturing, the horn symmetry is of vital importance, asymmetric horn leads to non-axial vibration which increases the horn stress and causes the horn invalidity.
 
A good tooling design is also important, the tolling has two main functions: align the parts below the welding horn and rigid support welding area. The rigid support help reflects the ultrasonic energy to the welding line, which is why the tooling is usually made of metal working pieces.
 
In order to increase the durability of the welding horn and prolong its service life, the welding horn surface could be dealt  with tungsten carbide treatment or chromium plating treatment. The tooling could be designed in sections to better match the products.




Welding parameters
 
Welding parameters affect the welding result in the welding process. These parameters include amplitude, welding pressure, trigger pressure, welding distance, and energy.
 
Different plastic material requires different amplitude, the amplitude is usually adjusted in the software percentage setting, or adjusted by changing the booster with different ratio. Welding pressure could be adjusted by the rotary button or the software setting. The pressure trigger is when the pressure reaches the setting value after a certain amount of pressure on the plastic parts, the ultrasound starts, the value is adjusted by the rotary button or the software setting.
 
Several control modes in the welding process:
Times mode
Energy mode
Distance/position welding mode
 
Different plastic uses different welding modes. For instance, the thin plastic material usually adopts energy mode, products with large dimensional tolerances are welded in distance mode, Products with high tolerance requirements are welded in position mode.
 
In addition, you could monitor all the parameters in the welding process, also you could set the parameter qualification range to avoid malfunctioning workpieces.
 
Plastic welding is special processing, in the early stage of product development, one should work closely with the ultrasonic equipment manufacturer, using their experience, to evaluate the product structure and welding line design and test the sample product to greatly improve the qualification rate in the later mass production process.



For more plastic welder, refer to below link: 


plastic welding machine click here

and here

How to choose the frequency of the ultrasonic cleaner?
 
The ultrasonic cavitation threshold value is closely connected with its frequency. Higher frequency comes with a higher threshold value and vice versa. The lower the cavitation threshold value, the more likely the cavitation is to occur. At the low frequencies, the interval time between the compression and sparsity of the liquid is longer so that the bubbles could grow to a larger size and enhance the cavitation strength, which is good for the cleaning. Therefore, the low-frequency ultrasonic cleaning equipment is often used in the cleaning of workpieces with large surfaces, or the surface of the workpieces is disdained seriously, which might damage or corrode the surface of the workpieces. So, it is inappropriate to use a low-frequency cleaner to wash the workpieces with high demanding surface finishing. Moreover, low frequency creates more noise. In the meanwhile, high-frequency ultrasound is more penetrating, which is suitable to clean the surface of the workpiece that is more complicated and has more blind holes or has stricter requirements on the surface.







On the other hand, the high-frequency ultrasound creates less noise so it is suitable for the cleaning of some small and high precision spare parts such as electronics, miniature bearing processing or magnetic material, etc. For some special workpieces like integrated circuit chips and silicon slices with coated membrane, the ultrasound with an even higher frequency would be a better choice. For some large workpieces such as automobile engines, valves, lower-frequency ultrasound could be applied. Normally the applicable frequency is within the range of 20-130kHz considering its effect and cost.
 
This brings us a question, what aspects should be we pay attention to before purchasing one specific ultrasonic cleaner that perfectly suits your needs?
 
1. Know well of your workpieces: the workpieces material, structure, shape, size, your cleaning quantity needs, cleaning result, and the procedure after the cleaning should be well known by you.
 
2. Dirt or filth to be cleaned: to be clear of the workpieces' oil or stain types such as ram drawing oil, polishing wax, carbon deposit, dust, fingerprint, etc.
 
3. Cleaning process: choose an appropriate cleaning process according to the attribution of the workpieces and stain condition, you could consult the equipment supplier for the suggestion. The cleaning process is a very important step before manufacturing the machine. It must be well chosen for it will have a long-term cleaning effect in the future.
 
4. Manual, semi-manual, or automatic mode: manual mode is usually suitable to wash small quantity workpieces with simple operation. The semi-manual mode could be used to clean large or heavy workpieces with middle or large quantities, this could reduce labor cost and enhance cleaning efficiency. Automatic mode is suitable to clean large quantity workpieces with stable and good cleaning results, but it requires a higher budget also. Users could choose the right model according to their own budget situation and other factors.
 
5. Cleaning tank size: the size depends on the workpieces cleaning quantity, structure, cleaning time, which means that a certain quantity of workpieces needs to be cleaned at a specific time. This could be calculated easily per your own cleaning requirements.
 
6. Ultrasonic power and frequency: the cleaning agents are long-term-used consumables. The Cleaning agents are divided into organic solvents and water-based cleaning agents. The choice of the cleaning agents is decided by the workpiece’s material and stain condition. The general principle is that the dirt can be cleaned quickly and thoroughly, and the appearance of the workpiece could remain basically undamaged.
 
In simple words:
 
1. First get to know about your cleaning purpose and the best way to clean your products
2. Decide your cleaning quantity so as to choose the corresponding power and volume
3. Know about the cleaning process-consult the equipment supplier
4. choose the most appropriate supplier by making a comprehensive comparison of price, cleaning process, and after-sale service, etc.
 
Of course, K&M tech always welcomes inquires all over the world.
 
Our products: 


ultrasonic cleaner

Welcome to our in-depth exploration of the latest advancements in ultrasonic metal welding techniques. In this article, we will delve into the innovative methods and applications that are revolutionizing the field of metal joining. From enhanced material compatibility to increased precision, these cutting-edge techniques are reshaping the way industries approach metal welding. Join us as we uncover the latest innovations and their potential impact on various manufacturing processes. Whether you are a welding professional or simply curious about the latest advancements in technology, this article will provide valuable insights into the world of ultrasonic metal welding.
to Ultrasonic Metal Welding

Ultrasonic metal welding is a solid-state bonding process that uses high-frequency ultrasonic vibrations to create a strong weld between two metal materials. This innovative technique has gained popularity in recent years due to its ability to produce high-quality welds without the need for additional heat, filler materials, or fluxes. In this article, we will explore the advanced techniques and recent innovations in ultrasonic metal welding and discuss its diverse applications across various industries.

KnMTech's Contribution to Ultrasonic Metal Welding

As a leading provider of advanced ultrasonic metal welding technologies, KnMTech has been at the forefront of developing innovative solutions for the metal joining industry. With a strong focus on research and development, KnMTech has introduced cutting-edge welding systems that offer improved precision, efficiency, and reliability. Our advanced techniques have enabled manufacturers to achieve superior weld quality and optimize their production processes, ultimately leading to cost savings and enhanced product performance.

Innovations in Ultrasonic Metal Welding

In recent years, there have been significant advancements in the field of ultrasonic metal welding, driven by the continuous demand for higher quality and greater efficiency in metal joining processes. One notable innovation is the development of multi-frequency ultrasonic welding systems, which allow for greater control over the welding process and the ability to weld dissimilar metals with varying thicknesses. Additionally, the integration of advanced monitoring and feedback systems has improved the real-time assessment of weld quality, ensuring consistent and reliable results.

Applications of Ultrasonic Metal Welding

The versatility of ultrasonic metal welding has made it a preferred choice for a wide range of applications across industries such as automotive, aerospace, electronics, medical devices, and consumer goods. In the automotive sector, ultrasonic metal welding is used for assembly and joining of complex components such as battery packs, electrical connectors, and sensors. In the electronics industry, it is utilized for bonding of microelectronic components and hermetic sealing of electronic packages. The medical device industry benefits from ultrasonic metal welding for creating sterile and leak-proof seals in surgical instruments and medical implants.

Future Trends and Challenges

Looking ahead, the future of ultrasonic metal welding is promising, with ongoing developments focused on further enhancing process control, increasing the scale of welding applications, and expanding the range of materials that can be successfully joined. However, there are still challenges to overcome, such as addressing the welding of dissimilar materials with large differences in melting points and thermal conductivity. Additionally, the adoption of ultrasonic metal welding in new industries and the education of operators on advanced techniques will be crucial for its widespread implementation.

In conclusion, ultrasonic metal welding continues to evolve with advancements in technology and innovations in applications, driven by the efforts of pioneers like KnMTech. With its proven benefits in terms of cost-effectiveness, precision, and environmental sustainability, ultrasonic metal welding is poised to play a vital role in the future of metal fabrication and manufacturing.

ConclusionIn conclusion, the advancements in ultrasonic metal welding have opened up a world of possibilities for various industries, from automotive to electronics. With our 9 years of experience in the industry, we continue to stay at the forefront of these innovations, providing our clients with the most advanced and reliable welding techniques. As we look to the future, we are excited to see how these innovations will continue to shape the way we approach metal welding, and we are committed to staying at the cutting edge of these developments. With our expertise and dedication to excellence, we are confident that we will continue to meet the evolving needs of our clients and drive further progress in the field of ultrasonic metal welding.