AWS G1.1M/G1.1 : 2006

GUIDE TO ULTRASONIC ASSEMBLY OF THERMOPLASTICS

American Welding Society

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Personnel
Foreword
List of Tables
List of Figures
1. General
    1.1 Scope
    1.2 Introduction
    1.3 Ultrasonic Assembly
    1.4 Process Description
    1.5 System Component Functions
    1.6 Systems for Applying Energy to Work
    1.7 Process Advantages and Limitations
    1.8 Safety and Health
    1.9 Units of Measurement
2. Referenced Documents
3. Terms and Definitions
4. Material Overview
    4.1 Polymers
    4.2 Property Effects
    4.3 Fillers, Alloys, and Additives
    4.4 Injection Molding Effects
    4.5 Post-Mold Characteristics
    4.6 Predicting Weldability
    4.7 Film and Fabric
5. Process Description
    5.1 Introduction
    5.2 Heating
    5.3 Pressure
    5.4 Intermolecular Diffusion
    5.5 Cooling and Solidification
6. Welding Equipment
Part A - Electrical System
    6.1 Power Supply/Generator
Part B - Acoustical System
    6.2 Converter
    6.3 Booster
    6.4 Horn
    6.5 Fixtures
Part C - Mechanical Delivery Systems
    6.6 Actuator
    6.7 Weld Distance Pretrigger
    6.8 Rigidly Mounted Stacks (Converter, Transducer,
         Booster, and Horn)
    6.9 Handheld Units
Part D - Process Controls and Outputs
    6.10 Controller
    6.11 Weld and Hold Controls
    6.12 Weld Modes/Primary Controls
    6.13 Weld Limits/Secondary Controls
    6.14 Weld Graphs
    6.15 External Interfacing
    6.16 Other Features
Part E - System Types
    6.17 Integrated System
    6.18 Component System
    6.19 Handheld System
    6.20 Automated System
7. Joint and Part Design
    7.1 Joint Design Characteristics
    7.2 Part Design Considerations
    7.3 Joint Types-Energy Director
    7.4 Joint Types-Shear
8. Welding Process Optimization
    8.1 Overview
    8.2 Optimization Method
    8.3 Selection of Machine Process Parameters
    8.4 Interrelationship of Process Parameters
9. Welding Process Troubleshooting
    9.1 Troubleshooting Overview
    9.2 Equipment Troubleshooting
    9.3 Part Troubleshooting
    9.4 Welding Troubleshooting
10. Testing
    10.1 Standardized Procedures
    10.2 Test Reports
11. Other Ultrasonic Techniques
    11.1 Staking
    11.2 Swaging
    11.3 Insertion
    11.4 Forming
    11.5 Degating
    11.6 Cutting and Trimming
    11.7 Spot Welding
Annex A (Informative) - Guidelines for the Preparation
                        of Technical Inquiries

Abstract

Defines the ultrasonic equipment and the processes for welding thermoplastic parts. It also describes staking, swaging, insertion, forming, degating, cutting, and trimming. Included are discussions on joint and part design, testing, and process optimization.