Ultrasonic Customized Horn with Coating for Welding Machine 

Before examining common causes of ultrasonic welding problems, let’s take a moment to understａnd the welding cycle itself. In ultrasonic welding, high-frequency vibrations are applied the surfaces of two parts by a vibrating tool, commonly called a “horn" or “sonotrode." Welding occurs as the result of frictional heat generated at the interface between the parts. The ultrasonic vibrations are created by a series of components—the power supply, converter, booster, and horn—that deliver mechanical vibration to the parts.

What's ultrasonic booster?

Ultrasonic booster, the important component of the ultrasonic vibration system is to amplify the mass displacement or velocity of the mechanical vibration and concentrate the ultrasonic energy on a small area. Ultrasonic booster is an important part of the ultrasonic vibration system. Its main function in the vibration system is to amplify the mass displacement or velocity of the mechanical vibration, and concentrate the ultrasonic energy on a small area, that is, the energy is collected. Also known as ultrasonic shift levers or ultrasonic concentrators.

Ultrasonic booster, as the name suggests, are functional components that match the amplitude of ultrasonic vibrations with ultrasonic transducers. Its main function is to change the amplitude of the transducer (generally increase), improve the vibration ratio, improve the efficiency, improve the mechanical quality factor, enhance the heat resistance, expａnd the temperature range, and prolong the service life of the transducer. The ultrasonic transducer adjusts the load matching between the transducer and the ultrasonic horn by installing a booster, which reduces the resonance impedance and makes it work at the resonant frequency to improve the electro-acoustic conversion efficiency. Reduces the heat generation of the ultrasonic transducer and improves the service life.

Using Finite Element Analysis software to analysis each horn's design in the most detailed and optimized manner to reach the best amplitude and life. 

Whether it is a standard or a customized horn, the highest quality materials and the best design and the most precise adjustments are used as the standard of design and manufacturing .

Various horn's frequencies range is from 15KHz to 100KHz which can be produced by our company. The type of horn includes step type, exponential type, rectangular type,round type, hollow type, and so on.

Ultrasonic Customized Horn with Coating for Welding Machine  is designed by finite element analysis (FEA) software to analyze the vibration state and stress distribution of each horn in detail, to ensure that each horn achieves the best quality to meet the needs of different applications of customers.