In ultrasonic welding, amplitude refers to the maximum displacement of the horn or sonotrode during the ultrasonic vibration cycle. It is a measure of the intensity of the ultrasonic energy being applied to the parts being welded.
Amplitude is typically measured in microns (μm) or thousandths of an inch (mils), and can range from a few microns to several hundred microns depending on the specific application and materials being welded. Higher amplitude generally results in greater welding energy and a stronger weld, but also increases the risk of damage or deformation to the parts being welded.
The amplitude of the ultrasonic vibration is controlled by the ultrasonic generator, which generates high-frequency electrical energy that is converted into mechanical vibrations by the transducer. The amplitude can be adjusted using the amplitude control on the ultrasonic welding equipment, which can vary the voltage and/or current supplied to the transducer.
Optimizing the amplitude for a specific application is important for achieving a strong and reliable weld. The appropriate amplitude depends on several factors, including the materials being welded, the joint design, and the desired strength and quality of the weld. Too little amplitude can result in a weak weld, while too much amplitude can cause damage to the parts or lead to flash around the joint. It is important to carefully select and adjust the amplitude for each specific application to ensure a successful and efficient welding process.
Amplitude is one of the most important variables within any ultrasonic application. The amplitude created by a system is a factor of the hardware of that system. The amplitude depends directly on the frequency of your hardware. All of the components of an ultrasonic system have an amplitude. These components work together to create the entire application’s amplitude.
Amplitude in ultrasonic welding:
1) A measure of how far a component’s face moves during ultrasonic vibration.
2) Can refer to: transducer, booster, or horn.
3) The amplitude of the front of the horn is the most influential parameter responsible for heating of the plastic.
4) Measured commonly as peak to peak value with units in microns. For a given amplitude, stress in the horn increases at higher frequencies.
Different types of plastic require different amplitudes. An ultrasonic stack is assembled to achieve an amplitude as close to a plastics ideal welding amplitude as possible. The ultrasonic generator can than tune the amplitude to a percentage of the hardware’s maximum for a precision weld.