Ultrasonic welding of thermoplastics in the near-field

Ultrasonic welding is one of the most popular techniques for joining thermoplastics because it is fast, economical, and easily automated. In near‐field ultrasonic welding, the distance between the horn and the joint interface is 6 mm or less. This study investigated the near‐field ultrasonic welding of amorphous (acrylonitrile‐butadiene‐styrene and polystyrene) and semicrystalline (polyethylene and polypropylene) polymers. High frequency ultrasonic wave propagation and attenuation measurements were made in order to estimate the dynamic mechanical moduli of the polymers. The estimated moduli were entered into a lumped parameter model in order to predict heating rates and energy dissipation. Experimental results showed that variations in the welding pressure had little effect on energy dissipation or joint strength; Increasing the amplitude of vibration increased the energy dissipation and the weld strength. For the semicrystalline polymers, increasing the weld time improved strength up to weld times greater than 1.5 s, where strength leveled off. For the amorphous polymers, the weld strength increased with Increasing weld time up to times of 0.8 s; for longer weld times, the power required was too high, causing overloading of the welder. Monitoring of the energy dissipation and static displacement or collapse provided valuable information on weld quality.